Conventional Belt Conveyors
Our evaluation approach to conveyors is a little different from most. We identify belt conveyors as complex systems and approach our analysis from a classical system-engineering viewpoint. In short, this means we try to look at a conveyor as a system first, which performs a specific function rather than a compilation of components. This may not sound like a big difference, but the process can produce different results. Probably the biggest difference in the process is the use of dynamic analysis techniques.
The term “dynamic analysis” is no more than the summation of all these mathematical pieces tied together in a working simulation of the system. This simulation is the most important tool of the systems engineer. With this functioning simulator which includes the flexible belt that interconnects all, we can easily change external conditions (i.e. material loads) and determine the expected results (system response). Once the simulator is built, we can also make changes to control logic and optimize control parameters. On a long belt conveyor, this evaluation and optimization process may not be possible by any other means (including on the actual conveyor) as it is very difficult to accurately evaluate the interaction of drives and components which may be thousands of feet apart.
Horizontal Curves
The old saying goes shortest path between two points is a straight line. But quite often, there is something in the way that precludes our extending belt conveyors in a straight line. If that’s the case, we can break flights into pieces and use the dreaded transfer station, or we can now simply curve the conveyor around the obstacle. This simple technology is very well tested and performs very well in many, many applications around the world.
Intermediate Drives
Distributing power between head and tail or even at one or more mid-points can greatly reduce the overall costs of an overland conveyor and allow it to negotiate a much tighter route through obstacles. Overland Conveyor Co has been involved in the pioneering of intermediate drive technology since 1985 and has developed sophisticated control algorithms for the most demanding applications with up to 11 drive locations.
Underground Conveyors
Underground conveyance provides unique challenges to the designer in terms of space, reliability and flexibility. Underground users have long been leaders in the demand for the newer technology such as intermediate drives and Variable Frequency Drives in order to solve the most difficult material handling problems.
Construction Tunneling
Attaching belt conveyors to the back end of tunnel boring machines to carry out tunnel muck is one of the most challenging of all belt conveyor applications. These belts are constantly advancing and are never the same two days in a row. They often require intermediate drives and negotiate tight horizontal curves while completing the 1 to 3 years construction projects.
Pipe Conveyors
These non-conventional belt conveyors totally confine the belt within idler rolls which allow for tighter radii and more efficient routes. By totally enclosing the material, environmental concerns can often be overcome easily. As this technology matures, it has been extended to very long (over 10 km) overland conveyors all around the world.
Metso Cable Belt (MCB)
Another non-conventional method of conveying materials over very long distances. The longest single flight conveyor in the world (30km) is of this type. The main feature is the separation of the load carrying belt from the strength member (wire rope). These ropes can now be removed from the load to go around intermediate drives or positively tracked in a horizontal curve.
Transfer Chutes
Most risk analysis will identify the transfer chutes as the biggest risk in any belt conveyor. Getting the material loaded and unloaded for a conveyor is often left to last in the design process but should be moved to a very prominent position as the ramifications of a poor or well designed chute is paramount to the long term success of material transport. Overland Conveyor Co has pioneered the development and use of Discrete Element Modeling to the simulation of bulk material flow through belt conveyor transfer chutes. Our extensive work in this field has included transfer design verification, capacity improvement, flow stream design for wear, plugging and dust mitigation, chute fabrication drawings and material characterization for use by you or us with our software. Our work can be as interactive as you wish, usually working from our offices with preliminary modeling results provided as part of the process. Deliverables include DEM results and a written report. Click here for further information or a proposal.