Measurement 63 (2015) 168–175

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

Analysis of influence of conveyor belt overhang and cranking

on pipe conveyor operational characteristics
Vieroslav Molnár a,⇑, Gabriel Fedorko a, Miriam Andrejiová b, Anna Grinčová c,
Marianna Tomašková b
a
Technical University of Kosice, Letna 9, 042 00 Kosice, Slovak Republic
b
Faculty of Mechanical Engineering, Technical University of Kosice, Letna 9, 042 00 Kosice, Slovak Republic
c
Faculty of Electrical Engineering and Informatics, Technical University of Kosice, Letna 9, 042 00 Kosice, Slovak Republic

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

Article history: Conveyor belt, which is installed in a pipe conveyor, is subjected to various processes dur-
Received 27 June 2014 ing its current operation, whereas these processes are causing a wear-out of the conveyor
Received in revised form 25 November 2014 belt. The wearing process of the conveyor belt is induced predominately by influence of the
Accepted 4 December 2014
transported material as well as due to improper operational conditions that are often
Available online 15 December 2014
caused as a result of an incorrect design of the idler housings. One of the possible conse-
quences of the idler housing incorrect design is an irregular guiding of the pipe shaped belt.
Keywords:
The incorrect guiding of the pipe shaped belt is manifested usually by an overhang and
Overhang
Cranking
cranking of the conveyor belt. There are presented in this paper the experimentally
Contact force obtained results based on a simulation of the cranking and overhang of the conveyor belt.
Rubber–textile conveyor belt The negative phenomena of the conveyor belt cranking and overhang were induced by
Idler roll means of an intentionally incorrect setting-up of the idler roller positions, in order to ana-
Regression models lyse their influence on the operational characteristics of the pipe conveyor. The experimen-
tally investigated influence was verified by means of the developed regression models
specified for description of a dependence among the normal contact forces and the tension
force, as well as by the regression models, which are describing interrelations among the
normal contact forces in two neighbouring idler rollers.
Ó 2014 Elsevier Ltd. All rights reserved.

1. Introduction for bulk material transport. If the transported goods have

Environmental aspects of bulk material transport are
relevant presently with regard to a protection of the sur-
roundings against pollution. A close interconnection
between the bulk material transport and the living envi-
ronment is evident. The producers and users of the belt
conveyor transport systems are looking for new solutions
in the given engineering area, in order to eliminate possi-
ble negative environmental impacts of the existing or
newly projected conveying systems, which are specified
⇑ Corresponding author. Tel.: +421 556023143; fax: +421 556028023.
E-mail address: vieroslav.molnar@tuke.sk (V. Molnár).
to be protected against the environmental influences or if
the environment has to be protected against dust origi-
nated from the goods being transported, the closed pipe
conveyor is just the suitable transport system or the sys-
tem of a first choice. The pipe conveyor is an enclosed
and curve shaped transportation system, which is specified
for all kinds of bulk materials. This conveyor system is
identical with a ‘‘classic’’ open trough conveyors in its
loading and discharging point. A significant difference
occurs behind the loading point, where the belt is formed
into its typical pipe shape by means of a special idler roll
arrangement over a certain distance and, finally, the pipe
shaped conveyor belt is guided through the hexagonal idler

http://dx.doi.org/10.1016/j.measurement.2014.12.013
0263-2241/Ó 2014 Elsevier Ltd. All rights reserved.
 V. Molnár et al. / Measurement 63 (2015) 168–175
housings. The pipe conveyors permit especially tight curve
radii and steep angles of inclination. This low-cost and
low-maintenance transport equipment also offers a possi-
bility to transport two different materials in the upper and
lower strand separately.
In addition, the correct conveyor belt alignment is
important in order to prevent that the transported product
is being spilled from the pipe conveyor along its length due
to the overlap incorrect position.
An incorrect position of the pipe shaped conveyor belt
in the hexagonal idler housings with the idler rolls is one
of the most frequent problems, which has to be solved just
after installation of the conveyor belt itself into the pipe
conveyor supporting structure during a testing operation.
There are several approaches how to set-up a correct posi-
tion of the pipe shaped conveyor belt and how to control it.
Taking into consideration the above-mentioned facts it is
very important to analyse all the external and internal
impacts that are influencing the conveyor belt.
Lodewijks et al. [1] discussed a nature of pipe rotation.
They also discussed possibilities for a correction of the pipe
rotation and limitations for a control of pipe orientation.
Maton [2] presented a theoretical approach how to analyse
the existing pipe conveyor. He also reviewed possible
advantages and disadvantages concerning installation of
a pipe conveyor with elliptical shaped tube, as well as he
emphasized an importance of understanding how the con-
veyor belt specification and construction are influencing
the operational characteristics of the piper conveyor, such
as twisting.
The new approaches to measuring and analysing of the
acoustic emission from a belt, at different conditions inside
an enclosure, investigated Fazenda et al. [3]. This method
allows an extraction of the useful diagnostic information
concerning operational conditions of the belt and indicates
the future research areas. Li et al. [4] proposed and verified
a system, which is able to locate a position of the faulty
idlers with a limited number of sensors what is important
for current operation of the belt conveyors. He and Li [5]
are oriented into the area of a non-linear modeling, simu-
lation and vibration analysis of a large scale conveyor sys-
tem. Kozhushko and Kopnov [6] studied the fatigue
behaviour of a fabric conveyor belt subjected to a shear
loading.
The conveyor belt simulation is a very difficult task. Hu
and Guo [7] suggested a new method for belt conveyor
dynamic design, i.e. the virtual prototyping technology.
The results confirm the correctness of a simplified virtual
prototyping and the feasibility of a heavy-duty belt con-
veyor virtual prototyping.
Determination of the total energy loss of the rubber
conveyer belts is a very difficult problem, especially in
the case of pipe conveyors, [8]. Kinoshita et al. [9] proposed
a method, which is applicable for estimation of the total
energy loss of the rubber conveyer belts on the idler rolls.
Maton [10] discussed and presented a method for estimat-
ing of friction between the belt and idlers, as well as for
determination of the power consumption. Liu and Wang
[11] proposed a method, which presents a fact that this
method offers a reasonable evaluation concerning quality
of the belt conveyor. Adolfo et al. [12] developed and
169
proposed the test methods and field measurements for
the energy-optimized conveyor belts. Reicks et al. [13]
compared the calculate and measure indentation losses
in rubber belt covers. Gallagher [14] researched low rolling
resistance for conveyor belts.
Many authors are applying the Finite Element Method
for modeling and simulation of the conveyor belt static
behaviour in the pipe conveyor idler housing [15,16]. Mar-
asová et al. [17] dealt with a model developed especially
for determination of the contact load values, which are
induced by an interaction of the pair: pipe conveyor belt
– idler rolls. Pang and Lodewijks [18] simulated stresses
on the six idler rolls and deformation of the belt caused
by a tension force, which is acting on both ends of the belt.
Qin et al. [19] presented a complete system of simulation
and calculation, which is specified for a steady state
visco-elastic stress analysis. Bocko et al. [20] researched a
complex material and performed experimental testing of
the conveyor belts, together with numerical analysis.
It is necessary to describe exactly the resistance forces,
especially the rolling resistance, in order to obtain the
accurate results from a computer simulation of the con-
veyor belt dynamic behaviour. You-fu and Fan-sheng [21]
developed a new two-dimensional semi-analytical method
based on the Maxwell’s model in order to perform the sim-
ulation process rigorously and efficiently and to solve the
rolling resistance of conveyor belts. Zamiralova and Lode-
wijks [22] presented a detailed approach to calculation of
the rolling resistance forces of the pipe conveyors, too.
An adequate attention is also paid to a determination of
the normal contact forces and concentrated loading forces
on each idler roll in the idler housing. The loading forces
depend on the mass of the transported material, pipe-
filling ratio as well as on the mass and stiffness of the belt.
Wennekamp et al. [23] created of various DIN standards.
Which will include the test methods and the use of test
results for the calculation of the belt width related inden-
tation rolling resistance of belt conveyors. The main reason
for performing of the research activities just in this area is a
fact that in spite of the several tens installed pipe convey-
ors worldwide, the knowledge base, which could be able to
describe the contact force relations in the pipe conveyor
belt, is still insufficient.
2. Materials and methods
The pipe conveyor, in comparison to the ‘‘classic’’ trou-
ghed belt conveyor, is able to transport material not only in
horizontal curves, but also in vertical curves thanks to its
special tubular construction. This attribute of the pipe con-
veyors is one of decisive factors with regard to their appli-
cation on the real operational conditions.
During a projection of the pipe conveyor trajectory it is
necessary to pay a special attention to a proposal of the
horizontal and vertical curves of the pipe shaped conveyor
belt. The curvature of horizontal and vertical pipe conveyor
bends has to be designed without any sudden changes of
direction, i.e. without a conveyor belt cranking. A curvature
trajectory of the piped belt should be continuous and
gradual.
170 V. Molnár et al. / Measurement 63 (2015) 168–175

If the curves of the pipe shaped belt are dimensioned

incorrectly, appears a negative phenomenon of the con-
veyor belt cranking. Such unfavourable situation causes
other negative consequences or unfavourable factors, too.
The primary negative consequence of the cranking
occurrence is an excessive loading of the pipe conveyor
belt. This fact causes consequently an excessive wear out
of the conveyor belt, together with creation of small cracks
on the upper and bottom cover of the conveyor belt. This
process is able to destruct the belt totally on the chance
of extreme situations.
The second negative phenomenon of the conveyor belt Fig. 1. Principle of the experiment performed on 8 m long section of the
conveyor belt.
cranking is increasing of the belt conveyor motional resis-
tance, which is arising on several guiding idler rolls. This
fact also induces the increased power-output requirements Table 1
concerning the pipe conveyor driving unit, together with a Parameters of the rubber–textile conveyor belt and the measuring
higher energy consumption. Afterwards, there is a real pos- conditions.
sibility of the driving unit overloading or destruction and a Rubber–textile conveyor belt EP500/3 HP 5 + 3 D
possibility of problems during the conveyor start-up pro- Diameter of pipe shaped belt 220 mm
cess, as well. Width of the belt 800 mm
The tertiary negative consequence of the pipe conveyor Length of the belt sample 8000 mm
belt cranking is an increased loading of the guiding idler Time of the belt relaxation 120 s
Distance between idler housings 1000 mm
rollers, bearings and a more intensive bending loading of
Ambient temperature 21 °C
the idler roller holders. Transported material Without material
Taking into consideration the above-mentioned facts it
is evident that the conveyor belt cranking is a very nega-
tive phenomenon, which causes a wide range of various The conveyor belt cranking can arise in the upper or
undesirable consequences. Therefore, it is necessary to bottom strand of the conveyor belt, in the range of pipe
analyse and to investigate this occurrence. shape closing or opening, in the area of conveyor belt

Fig. 2. Positions of the normal contact forces on the idler rolls in the hexagonal idler housings No. 1, No. 2.
 V. Molnár et al. / Measurement 63 (2015) 168–175
curvature or there is also a possibility of the conveyor belt
overhang through idler roller in the bottom strand of the
pipe conveyor.
An experimental measuring and investigation of the
given problem is very difficult or it is almost an impossible
task on the real operational conditions. There are dispos-
able only visual inspection methods and indirect methods
based on measuring of electric energy consumption of the
conveyor driving unit.
However, more favourable situation is on the laboratory
conditions. In our case, the cranking and overhang phe-
nomenon of the conveyor belt, which occurs in the phase
of pipe shape forming, was simulated using a testing
equipment installed at the Faculty of Mining, Ecology, Pro-
cess Control and Geotechnology, Technical University of
Kosice, in Slovakia. The applied experimental testing
equipment was designed and used in the framework of a
long-time research of the pipe conveyors, which is per-
formed at our workplace. The main purpose of our investi-
gation was to identify an influence of the cranking and
overhang of the pipe shaped conveyor belt on the value
and behaviour of the normal contact forces measured on
the individual idler rolls. There were applied the mathe-
matical regression methods for evaluation of the measured
values.
2.1. Conveyor belt and measuring method
Measuring of the normal contact forces was performed
in order to identify the individual forces that are induced
due to acting of the conveyor belt on the individual idler
rolls situated in two idler housings, namely in the area of
pipe formation and for the piped belt, according to Fig. 1.
The important parameters of the investigated rubber–tex-
tile conveyor belt, as well as the measuring conditions, are
summarized in Table 1. The individual positions of the nor-
mal contact forces on the idler rolls in the hexagonal idler
housings No. 1 and No. 2 are in Fig. 2.
The measured data were recorded continuously by
means of the Labview software using the sampling fre-
quency 0.01 kHz. The measuring process was performed
according to the time behaviour, which is presented in
Fig. 3.
Fig. 3. Data selection method.
171
3. Theory/calculation
3.1. Regression models
A relation between the explained variable y (i.e. the
normal contact force) and the explaining independent var-
iable x (i.e. the tension force) can be described in general
by means of a simple regression model in a polynomial
form
y ¼ b0 þ b1 x þ b2 x2 þ . . . þ bk xk þ e; ð1Þ
where b0 is the so-called intercept, the coefficients bj for
j = 1, 2, . . ., k are parameters of the regression model, e is
a random component of the regression model and k is a
polynomial degree.
The point estimation of the regression model is a
regression function, which is written in the form
Y ¼ b 0 þ b 1 x þ b 2 x2 þ . . . þ b k xk ; ð2Þ
where Y is a theoretical value of the dependent variable, b0
is an estimation of the constant, b0 and bj is a point estima-
tion of the regression parameter, bj for j = 1, 2, . . ., k.
The maximum polynomial degree, considered in our
case, is k = 2. Thus, the regression model form is
y ¼ b0 þ b1 x þ b2 x2 þ e ð3Þ
and the point estimation of the regression model is
Y ¼ b 0 þ b 1 x þ b 2 x2 ð4Þ
The coefficients of parameters are estimated by means of
the least square method.
3.2. Method for evaluated data selection
The first step, which has to be accomplished for a statis-
tical data processing, is a categorisation and selection of
the collected data, because the data obtained immediately
after the recording process represent usually a large
amount of the various values without any periodicity and
regularity. Therefore, the measured data processing is a
necessary step, in order to obtain a clear, well-arranged
form.
The method, which was applied for selection of the
measured data, with respect to their next processing, is
illustrated in Fig. 3. There was found the point (1) among
the measured data, which represents the required tension
force. The first 10 s of the data recording were left out due
to an initial stabilisation, (2). Thus, for the consequential
data processing it was selected the following 60 s time
interval from the whole time record, (3).
4. Results
The measured data were recorded during the whole
measuring process, (Fig. 4). Tensioning of the conveyor belt
sample was realised by means of a gradual increasing of
the tension force with the constant increment 6000 N.
The conveyor belt sample was relaxed during the time
interval approx. 120 s after each increasing of the tension
force. The measuring process started with the initial
172 V. Molnár et al. / Measurement 63 (2015) 168–175

Table 3
Regression models – idler housing No. 1.

Normal Regression model Adjusted R-

contact force squared
ID1 Y = 3.0072 + 0.0237x2.44E07x2 0.9995
ID2 Y = 5.8710 + 0.0082x 0.9930
ID3 Y = 19.796 + 0.0256x2.80E07x2 0.9992
ID5 Y = 8.4309 + 0.0625x1.46E06x2 0.9754
ID6 Y = 101.338 + 0.0484x9.19E07x2 0.9869

position IDX (X = 1, 2, ... 6) of the idler housing No. 1 and

Fig. 4. Time behaviour of the tension force.
tension force value 4000 N and the final reached tension
force was 28,000 N. The real time behaviour of the tension
force, during the whole performed experiment, is illus-
trated in Fig. 4. The important numerical characteristics
of the obtained tension forces are in Table 2.
A cranking of the conveyor belt was simulated by
means of a total overhang on the idler roll ID5 and by a
partial cranking on the idler roll ID4.
There were investigated three basic dependences based
on the values obtained during the experiment.
The regression model I represents dependence among
the values of normal contact forces on the idler rolls ID1–
ID6 of the idler housing No. 1 and the values of considered
tension forces.
The regression model II represents dependence among
the values of normal contact forces on the idler rolls
ID7–ID12 of the idler housing No. 2 and the values of con-
sidered tension forces.
The regression model III represents dependences
among the values of measured normal contact forces on
the idler rolls of idler housing No. 2 and the values of nor-
mal contact forces on the idler rolls of idler housing No. 1,
concerning the corresponding pairs of idler rolls. The corre-
sponding pairs of the normal contact forces on the idler
rolls of idler housing No.2 and idler housing No. 1 were
selected in a direction of the tension force according to
Fig. 2, namely they are these pairs of the idler rolls: ID7–
ID1, ID8–ID2, ID9–ID3, ID10–ID4, ID11–ID5 and ID12–ID6.
4.1. Regression models I and II
4.1.1. Regression model I
The point estimations of the regression models describe
dependence between the normal contact force at the
the selected tension force. These point estimations are
summarized in Table 3. In order to verify the statistical sig-
nificance of the model, the F – test of statistical significance
was applied. The resulting p-value is less than the consid-
ered significance level in all models. It can be supposed
from this reason that the proposed regression models are
statistically significant.
A statistical significance of the individual parameters in
the regression models was verified using the test of statis-
tical significance for the regression parameter. All parame-
ters of the proposed regression models are statistically
significant.
A quadratic dependence was not confirmed for the nor-
mal contact force position on the idler roll ID2. In the case
of the normal contact force position on the idler roll ID2, an
overlapping of the conveyor belt occurred during its shap-
ing into the pipe form. A suitable model could not be found
for the normal contact force position on the idler roll ID4,
because the idler roll position ID4 is the point of simulated
partial cranking of the conveyor belt, where the resistance
forces are overcome during a gradual increasing of the ten-
sion force (overhang of the conveyor belt through the
neighbouring idler roll ID5 and cranking on the idler roll
ID4, according to Fig. 5) and, consequently, the measured
normal contact forces are changed discontinuously or sud-
denly (Figs. 6 and 7). It is not possible to find a suitable
model for description of the above-mentioned situation
by means of the least square method.
4.1.2. Regression model II
The point estimations of the regression models, which
describe dependence between the normal contact forces
at the position IDX (X = 7, 8, ... 12) on the idler housing
No. 2 and the selected tension force, are presented in
Table 4. Analogically with the normal contact force posi-
tion on the idler roll ID2, a quadratic dependence was also
unconfirmed between the output normal contact force and
the input tension force on the idler roll position ID8 for the
normal contact force. The reason was the same as it was on

Table 2
Numerical characteristics of the tension force (relaxation time 60 s).

Tension force [N] TF1 TF2 TF3 TF4 TF5

Average 3829.31 9508.12 15718.48 21118.21 27599.25
S.D. 59.65 99.57 139.98 145.34 174.67
Maximum 3991.66 9761.39 16067.95 21481.35 28037.43
Minimum 3707.86 9322.74 15499.84 20883.43 27320.11
Range 283.80 438.64 568.11 597.93 717.32
 V. Molnár et al. / Measurement 63 (2015) 168–175 173

Fig. 5. Simulated conveyor belt cranking and overhang.

the idler roll position ID2, i.e. the conveyor belt overlap-
ping during its shaping into the piped form on the idler roll
position ID8.

4.2. Comparison of mutually related normal contact forces

and regression model III

The normal contact forces on the idler housing No. 2 are

Fig. 6. Time behaviour of the normal contact force on the idler housing
No. 1 – tension force TF3.
changed markedly in comparison with the idler housing
No. 2. This fact is evident from analysis of the measured
normal contact forces on the individual idler rolls in the
whole range of the considered tension forces. The average
values of the normal contact forces on all idler rolls,
obtained during the relaxation time interval 60 s, are in
Table 5. Fig. 8 illustrates a time behaviour of the normal
contact forces for a pair of the normal contact force posi-
tions on the idler rolls ID9–ID3.
The normal contact force value on the idler rolls of the
idler housing No. 2 decreased almost in all cases (Table 5).
Only for the normal contact force positions on the idler
rolls ID10–ID4, at three tension forces (TF1, TF4 a TF5),
the normal contact force value increased (Fig. 9). This phe-
nomenon occurred just in such place where an overhang of
the conveyor belt was simulated (it is a position of the nor-
mal contact force on the idler roll ID4). Table 6 summa-
rized finally a decrease or increase of the measured
values for the normal contact forces on the idler housing
No. 2. The sign () represents a decrease and the sign (+)
means an increase of the normal contact force, which is
measured on the ID position of the idler housing No. 2,

Table 4
Regression models – idler housing No. 2.

Normal Regression model Adjusted R-

contact force squared
ID7 Y = 5.3840 + 0.0063x7.22E08x2 0.9983
ID8 Y = 15.3520 + 0.0020x 0.9960
ID9 Y = 36.9533 + 0.0111x1.76E07x2 0.9987
ID10 Y = 56.4993 + 0.0152x2.34E07x2 0.9997
ID11 Y = 53.3848 + 0.0101x9.44E08x2 0.9993
Fig. 7. Time behaviour of the normal contact force on the idler housing ID12 Y = 9.4372 + 0.0171x2.94E07x2 0.9971
No. 1 – tension force TF3 (Detailed).
174 V. Molnár et al. / Measurement 63 (2015) 168–175

Table 5
Resulting average values of the normal contact force [N] for the individual tension forces.

TF ID7 ID 1 ID 8 ID 2 ID 9 ID 3 ID 10 ID 4 ID 11 ID 5 ID 12 ID 6
TF1 17.09 91.72 22.38 33.48 2.04 112.38 111.17 75.93 91.32 208.99 49.69 284.11
TF2 50.03 204.38 33.57 83.25 54.71 241.38 180.38 239.37 139.85 446.27 131.02 454.90
TF3 75.09 315.12 47.01 139.52 93.68 348.27 238.06 303.54 191.34 641.28 183.77 639.01
TF4 96.03 398.97 57.93 185.52 117.73 437.04 273.29 256.49 224.62 632.62 219.35 728.11
TF5 114.61 471.16 68.16 225.02 136.07 512.17 298.73 254.41 261.60 613.65 239.09 728.10

Only for the normal contact force positions on the idler rolls ID10–ID4, at three tension forces (TF1, TF4 a TF5), the normal contact force value increased.
This phenomenon occurred just in such place where an overhang of the conveyor belt was simulated (it is a position of the normal contact force on the idler
roll ID4).

compared to the corresponding position on the idler hous-

ing No. 1.

4.2.1. Regression model III

The regression models of dependence among the
related contact forces of the idler housing No. 2 and No.
1 are presented in Table 7. The statistical significance of
the individual parameters for the regression models, as
well as for the model itself, was verified using a testing
of the corresponding hypotheses.
There was detected a linear relation among the corre-
sponding contact forces, which is resulting from analysis
of their mutual interrelations. The low-level values of the
coefficient Adjusted R-squared, in the case of ID10–ID4
and ID11–ID5, are evidently caused due to a simulation
of the conveyor belt cranking and overhang (Fig. 5).

Fig. 8. Time behaviour of the normal contact forces for a pair of the
normal contact force positions on the idler rolls ID9–ID3. 5. Discussion

The measuring process monitored an influence of the

Fig. 9. Time behaviour of the normal contact forces for the pair ID10–ID4.
simulated cranking and overhang of the conveyor belt
sample with regard to the values and time behaviour of
the normal contact forces on the individual idler rolls for
both idler housings. The obtained results confirm an
important fact that the phenomenon of cranking and over-
hang of the conveyor belt, which is caused due to an
improperly installed hexagonal idler housing, is relevant
in respect to the contact force values, namely on such idler
roll, where the conveyor belt cranking or overhang is local-
ised. It is possible to postulate a hypothesis that the con-
veyor belt cranking and overhang, which is occurring
during the pipe conveyor operation, is a harmful opera-
tional status and it causes also other negative conse-
quences. The most important negative consequences of
the conveyor belt cranking or overhang are increasing of
the motional resistances and overloading of the conveyor
driving station, with a possibility of its total malfunction.

Table 6
Summarizing of an average decrease ()/increase (+) of the corresponding normal contact forces.

Pairs of contact forces TF1 (%) TF2 (%) TF3 (%) TF4 (%) TF5 (%)
ID7–ID1 81.36 75.52 76.17 75.93 75.68
ID8–ID2 33.08 59.67 66.31 68.77 69.71
ID9–ID3 98.18 77.38 73.10 73.06 73.43
ID10–ID4 +46.52 24.64 21.13 +6.55 +17.42
ID11–ID5 56.30 68.66 70.16 64.47 57.37
ID12–ID6 82.50 71.19 71.24 69.87 67.16

Three tension forces (TF1, TF4 a TF5) where the normal contact force value are increased for the normal contact force positions on the idler rolls ID10–ID4.
 V. Molnár et al. / Measurement 63 (2015) 168–175
Table 7
Regression models – idler housing No. 2 versus idler housing No. 1.
Dependent Independent Regression model Adjusted
variable y variable x R-squared
contact contact force
force
ID7 ID1 Y = 4.4142 + 0.2531x 0.9998
ID8 ID2 Y = 13.9965 + 0.2386x 0.9993
ID9 ID3 Y = 30.2606 + 0.3364x 0.9852
ID10 ID4 Y = 64.0172 + 0.6918x 0.5197
ID11 ID5 Y = 16.6942 + 0.3246x 0.7270
ID12 ID6 Y = 56.8458 + 0.39060x 0.9768
The low-level values of the coefficient Adjusted R-squared, in the case of
ID10–ID4 and ID11–ID5, are evidently caused due to a simulation of the
conveyor belt cranking and overhang.
Another possible negative consequence is the increased
local loading and wearing of the conveyor belt, which is
manifested usually in the form of a visible longitudinal
trail on the conveyor belt surface. This form of damage is
created after a longer operational time. The increased load-
ing also causes a negative impact on the idler rolls as well
as on the whole hexagonal idler housing, which is situated
in the area of the conveyor belt cranking or overhang,
together with a danger of the idler roll ejection out from
the idler housing. This situation induces a possibility of
longitudinal cutting of the conveyor belt.
The above-mentioned negative occurrences, i.e. the
conveyor belt cranking and overhang, are able to cause
problems during the start-up process of the pipe conveyor,
as well. The motional resistance can be increased very
intensively due to the conveyor belt cranking or overhang
and in such way it has a potential to exceed a traction abil-
ity of the pipe conveyor driving unit. This fact is accented
in the case of low ambient temperatures, especially.
6. Conclusions
Taking into consideration all the described facts,
together with the obtained experimental results, it is pos-
sible to say that the conveyor belt cranking and overhang is
a serious problem, which cannot be neglected in any case.
The presented results discovered the primary conse-
quences of the cranking and overhang. These consequences
are more serious in a real situation, i.e. if the pipe conveyor
is transporting a real material. The experimentally
obtained results should be enriched or supplemented in
the framework of next research works scheduled in the
given investigation area. It is necessary to apply a high effi-
cient combination of the experimental measuring on the
real conditions and laboratory conditions, together with
application of the modern software tools specified for a
computer simulation, in order to extend the already
obtained information and to gain new facts.
Acknowledgements
This work is a part of these projects VEGA 1/0922/12,
VEGA 1/0085/12, VEGA 1/0258/14, FR-TI4/310, SK-CZ-
175
2013-0169. The article was prepared within the invitation
OPVaV-2012/2.2/08-RO named ‘‘University Science Park
TECHNICOM for Innovation Applications with the
Support of Knowledge-Based Technologies‘‘ – code ITMS
26220220182.
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