Engineering Failure Analysis 36 (2014) 3038

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Engineering Failure Analysis

journal homepage: www.elsevier.com/locate/engfailanal

Failure analysis of belt conveyor damage caused by the falling

material. Part I: Experimental measurements and regression
models
Gabriel Fedorko a,, Vieroslav Molnar a, Daniela Marasova a, Anna Grincova b, Miroslav Dovica c,
Jozef Zivcak c, Teodor Toth c, Nikoleta Husakova a
a
Faculty of Mining, Ecology, Process Control and Geotechnology, Technical University of Kosice, Park Komenskeho 14, 042 00 Kosice, Slovak Republic
b
Faculty of Electrical Engineering and Informatics, Technical University of Kosice, Letna 9, 042 00 Kosice, Slovak Republic
c
Faculty of Mechanical Engineering, 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: The most common case of conveyor belts damage is their puncture by falling sharp mate-
Received 10 July 2013 rial. One of the ways, how to minimize this type of damage, is using of suitable type of con-
Received in revised form 20 August 2013 veyor belt. Therefore, the analysis of conveyor belts on the part of their puncture resistance
Accepted 20 September 2013
is an important factor for their use in operation conditions. The aim of the paper is to deter-
Available online 2 October 2013
mine the dependence among the weight of sharp material falling on the conveyor belt,
shatter height and force conditions in the conveyor belt on the base of experimental mea-
Keywords:
surements by the help of regression mathematical model and to determine conditions
Conveyor belt
Test device
under which the conveyor belt is damaged. The experimental results enable the operator
Experimental measurement of a conveyor belt to set the shatter height and maximum weight of falling weight below
Regression model the threshold values in order to prevent conveyor belt damage.
2013 Elsevier Ltd. All rights reserved.

1. Introduction

Belt conveyors are machines for continuous transport [1]. Belt conveyor is a commonly used equipment of continuous
transport; it has a high efciency and large conveying capacity, simpler construction, small amount of maintenance. Can
be achieved at different distances, different materials transportation [2]. Belt conveyor is widely used in mine, coal, chemical
industry, ports, and power plants [3]. In the belt conveyor, as the conveyor belt is traction components, transmit power and
motion, also is carrying components, support material load [2]. One of the main causes of damage and often end the life of
conveyor belts is their dynamic stress. Dynamic analysis is the key to decide whether the design is rational in technique, safe
and reliable in running, feasible in economy. It is very important to study dynamic properties, improve efciency and pro-
ductivity, guarantee conveyor safe, reliable and stable running [4]. The dynamic characteristics of a belt conveyor are deter-
mined to a large extent by the properties of the belt [5].
Dynamic stress causes fatigue strength functions in shear loading of fabric conveyor belts. Kozhushko and Kicks [6] dealt
with functions fatigue strength in shear loading of fabric conveyor belts. They concluded that the fatigue phenomenon of
belts is explained by the decrease of shear strength, which is determined as an ultimate angle initiating the lamination fail-
ure of the central rubber layers [6].

Corresponding author.
E-mail address: gabriel.fedorko@tuke.sk (G. Fedorko).

1350-6307/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.engfailanal.2013.09.017
 G. Fedorko et al. / Engineering Failure Analysis 36 (2014) 3038 31

Cheng and Du [6] researched force state of belt conveyor during horizontal turning section to improve the design level of
belt conveyor with horizontal turning. Kumar [7] presented the review of belt conveyor design modication and latest tech-
nologies or methodologies used in different applications to reduce failures, maintenance cost and equipment related fatal
accidents occurs during operation.
For dynamic analysis of conveyor belts it has proved use of the nite element method (FEM). Hatala and Maras [9] in their
research focused on the application of the FEM numerical modeling stressstrain state in conveyor belts. Pascual et al. [10] pre-
sented a methodology to compute dynamic stress distributions on large conveyor belts considering a viscous-damping model.
The next author who dealt with the possibilities of FEM application within the frame of detailed research of the conveyor
belts problem was Lodewijks [8,9]. Fedorko and Ivanco [10] researched by FEM the force ratios in conveyor belt of classic belt
conveyor. By application of FEM for research of belt conveyors one of the key factor is determination of right material prop-
erties of conveyor belts. This problem was solved by the work of Mazurkiewicz [11].
Conveyor belt is very important for belt conveying operator also on the part of economy. For this reason it is necessary to
pay increased attention to research of causes which cause its degradation and damage.
Romani [12] dealt with the ability to control the drive acceleration torque providing a smooth soft start while maintaining
belt tensions within specied safe limits which are critical for belt conveyors performance. Zimroz and Krl [13] deal with
failure analysis for condition monitoring. Mazurkiewicz [14] also dealt with the problem of conveyor belts damages.
One of the main reasons for conveyor belt wear is the stress caused by the impact of lumpy material [15].
Impact of material on the conveyor belt is caused in many cases not only wear, but also conveyor belt damage. This prob-
lem was solved in the past not only in theory [1922], but also by testing in laboratory conditions [2326]. In theory, the
effort of authors is oriented to the creation of mathematical models with the aim to describe the properties of conveyor belt.
Till now it was described mathematical apparatus for determination of a reliability of belt conveyors using the renewal the-
ory [16,17]. Regression models in the area of conveyor belt breakdowns were solved only marginally [18,19]. The most atten-
tion is in mathematical modeling by FEM [20,810].
Research of damaged conveyor belts can be realized directly during the operation of belt conveyors, what is often almost
impossible or strenuous for realization or it is possible to use special test devices. Aldrich et al. [21] realized online analysis of
coal on a conveyor belt by use of machine vision and kernel methods. On the other hand Fiset and Dussault [22], Ballhaus
[23,24], Flebbe [25] and Hardygora [26] dealt with analysis of the causes of belt conveyors damages in laboratory conditions.
Damage of conveyor belt leads to its gradual destruction and due this fact we can monitor huge economic losses for users.
Therefore the effort of producers is to produce and interest of customers is to buy conveyor belt wit the greatest damage
resistance. The part of the article is a methodology, which can be used by conveyor belts tests associated with the assessment
of their damage resistance and breakdown creations in extreme cases.

2. Material and methods

2.1. Problem formulation

A conveyor belt changes its shape and size under the thumb of external load what means that it is deformed. Mechanical
properties express the relation among the size of acting external force and caused deformation, which include elastic and
deformational characteristics characterized by the modulus of elasticity, modulus of deformability and strength properties,
for example strength in compression, strength in tensile, strength in shear. Dimensional, functional, physical, mechanical
and special test methods are determined for the testing of basic properties of conveyor belts with textile cords and cover
layers from rubber.
Shock tests, which are the object of the research in this work, belong to special tests realized for purpose of overall assess-
ment of conveyor belts intended for special use, primarily for bulk material conveying in hard operation conditions in open-
cast quarries. They are very specic are of testing, and until now unmodied by any standards or regulations. The aim of
shock test is to determine the destructive resistance of a conveyor belt with regard to the conditions, in which the belt will
work (lumpiness of the conveying material, its shape and so on).
At present, there is no clear way of determining or evaluation of conveyor belts breakdown resistance. In practice, a con-
veyor belt is often exposed to impact of sharp material on its surface, especially in the place of conveyor lling or on shifting.
It occurs to their damage and in some cases conveyor belt is not able to the next operation. Its results are no small economic
damages which are related to the necessary of damaged belt exchange and created non-operating states. The paper is aimed
at the problem of rubbertextile conveyor belt damage by falling material. The aim is to determine the dependence among a
weight of material falling on the conveyor belt, shatter height and force ratios of conveyor belt by regression mathematical
model and to determine conditions by which it creates a damage of conveyor belt. For a more detailed study of the conveyor
belt after realization of experiments it was applied a method of industrial computed tomography.

2.2. Description of the experiment

Laboratory experiment is an appropriate means of determining the shock and tension forces during material impact on a
conveyor belt, i.e. for determination, respectively verication of use properties of investigated object conveyor belt
32 G. Fedorko et al. / Engineering Failure Analysis 36 (2014) 3038

resistance against rip. This experiment and its results enable to determine conveyor belt impact force and tension force at
the moment of sharp material simulated impact. Laboratory experiment realizes by the test device designed at the Logistics
Institute of Industry and Transport.

2.3. Description of the test device

The test device simulates the impact of the sharp material on the conveyor belt. Principled it is a drop hammer with
weight falling from a certain height, which is known to us on a conveyor belt. The device (Fig. 1) consists of a tower and test
board.
The construction of the tower is created from the metal truss construction, at the end of which is hoisting winch of the
drop hammer. The winch with the xed and free pulley create pulley block of the tower. The drop hammer can be lifted to a
maximum height 2.6 m. It is led by two parallel lines, which are formed from single-strand steel ropes of closed construction.
The weight of the drop hammer may vary from 40 kg to 300 kg what is the capacity of the lifting winch. Adding or remov-
ing of classic calibrated weight with the weights 520 kg realizes the change of its weight. Manipulation with the drop ham-
mer is enabled by free pulley of the pulley block. By changing of the height of the drop hammer it is monitored the change of
drop energy. The drop hammer is sinking by free fall. We attach impactors to the end of the drop hammer (Fig. 2). During the
test it was used impactor B, the Fig. 2. For the next experiments it was used impactors A, C, the Fig. 2 which are possible to
simulate other types of falling material. It was determined from the results of the measurements that the effect of the impac-
tor type is negligible on the results.
The test board is a metal construction created by U proles in which are moving hydraulic jaws for clamping of the con-
veyor belts sample. The construction of the clamping board was designed so that it creates solid unit resistant to impacts.

2.4. The test specimens

Sampling of conveyor belts by general applicable conditions is preceded by preparation of the test specimen. Sampling for
rubbertextile conveyor belts testing is realized at least 500 mm from the end of the produced conveyor belt. The length of
the conveyor belts sample must be such that of this it is possible to prepare test specimens for all required tests.
The test specimen is die-cut or cut-out from the sample of the conveyor belt at the points of uniform distributed at the
direction of its width, and the minimum distance from the edges of the belt must be 100 mm. We recommend using for cut-
ting out a knife with cuttingwedge angle not more than 18. For the purpose of laboratory experiments of which results are
presented in this paper, it is cut out the test specimen with dimensions 1400  600 mm from the sample of the rubbertex-
tile conveyor belt (Fig. 3).
The test specimens are tested at least 5 days after the production of the conveyor belt. Before the test they must be con-
ditioned for 3 days by temperature (23 2) C and relative air humidity (650 5)%, if the condition period is not specied
otherwise. The tests are realized by the temperature (23 2) C and relative air humidity (65 5)%. Each test specimen must

Fig. 1. The test device with the detail of the drop hammer with impactor.
 G. Fedorko et al. / Engineering Failure Analysis 36 (2014) 3038 33

Fig. 2. Shaped of impactors.

be controlled after the test at the point of the testing. If it is determined a material defect, the result does not regard and
there is recorded a kind of error in the record [27,28].

2.5. Basis of the test

The test specimen (conveyor belt type P 1600/5 + 2) is inserted into the space among hydraulic jaws and it is rmly sta-
pled. After pressing by hydraulic jaws the test specimen is strained by the force, which is equal to 1/10 strength of the belt
what corresponding with allowable stress of the conveyor belt in operation. After the test specimen tension the drop ham-
mer is freed on which it can be additional weight, but the drop hammer falls out on the test specimen. After the test it is
visually determined the rate of the test specimen damage and it is subtracted the size of the shock and tension force at
the moment of the impact. Subtracted data are subsequently appreciated with the aim to determine the dependence among
the size of shock force and the test specimen damage.

2.6. Evaluation of the test

Classication of the tests results from the impact stress is not currently dened by any standards or regulations. By the
evaluation we use all available mathematical, physical and statistical procedures.
After the tension of the test specimen and drop hammer release it is measured the size of tension and shock forces by the
help of two strain-gauge scanner. By the help of laser sensor it is measured the actual height of the drop hammer in regard of
the top layer of the test specimen. An electronic device records the whole time slope of the measurement, actual height of
individual time points, the size of the tension and shock force (Fig. 4). During one measurement cycle it was used the sam-
pling frequency 1000 Hz. The duration of the measurement of one impact test (10 s) results from the request of solver to
record completely the full test course, also with grading margin. This time exactly sufces to impact of the drop hammer
by maximum shatter height and maximum possible weight by free fall and at the same time it reects several times.
Evaluation of the test in the case of determination of the breakdown is based on a visual control of the test specimen and
control by metro-tomograph. From the measurement recording we determine in which size of the tension and shock force it
reaches a breakdown, so the damage of the test specimen and it is determined a disruptive energy. In the case of mathemat-
icalphysical model creation the measured data are next presented to the tables, graphs (Fig. 5), where the output creates
dependence of all parameters affecting the test results.

Fig. 3. Preparation of the test specimen.

34 G. Fedorko et al. / Engineering Failure Analysis 36 (2014) 3038

Fig. 4. Dependence of the shock force Fi at the time of the drop hammer impact on the conveyor belt.

3. Theory/calculation

3.1. Design of the regression function

A regression analysis helps to nd a mathematical model, which determines the correlation of two or more parameters.
This model is an expression of the assumption of dependence and it presents starting parameters for the regression analysis.
It is described by regression function (1), which can have various forms.
y b0 x0 b1 x1 . . . bn xn : 1

Within the frame of our research for conveyor belts resistance we applied as a based for the regression analysis applies
data (Table 1), which were obtained by experimental measurements on the test device (Fig. 1).
Within the frame of the next procedure, the regression function (1) was replaced by selected regression function (2).
Y b0 x0 b1 x1 . . . bn xn : 2

Coefcients b0 ; b1 ; . . . ; bn are estimates of the unknown coefcients b0 ; b1 ; . . . ; bn . For the estimate of these coefcients it
was used the least squares method, by which we minimize the residual sum of squares for deviations (3).
X
n
SR yi  Y i 2 3
i1

Fig. 5. Compare of shock forces values obtained experimentally and by calculation using the model (10).
 G. Fedorko et al. / Engineering Failure Analysis 36 (2014) 3038 35

Table 1
Maximum values of the shock force Fi [kN] depending on the weight m and shatter height h.

m [kg]/h [m] 50 60 70 80 90 100

0.2 3.100 3.806 4.542 5.268 5.582 6.563
0.4 4.768 5.631 6.651 7.603 8.329 9.633
0.6 6.082 6.995 8.260 9.761 10.762 12.086
0.8 7.250 8.123 9.741 11.164 13.450 14.431
1.0 8.456 9.516 11.301 13.322 15.461 16.726
1.2 9.437 10.801 12.871 14.970 17.315 18.502
1.4 10.575 12.292 14.519 16.657 19.316 21.710
1.6 11.586 13.616 16.000 18.227 20.905 23.387
1.8 12.606 14.999 17.462 20.130 22.857 25.123
2.0 13.675 16.137 18.708 21.435 24.447 27.370
2.2 14.038 17.344 19.993 23.220 26.222 29.302
2.4 15.382 18.080 21.386 24.103 28.115 31.068
2.6 16.010 19.502 22.592 29.195 32.383

The index of determination (4) was used as the characteristics of sententious for the regression function, where the Sy (5)
, and y
is the sum of squares of deviations yi  y  in the Eq. (5) is the arithmetic average of the measured values of the
variable.
SR
I2 1  4
Sy

X
n
Sy 2
yi  y 5
i1

From the methods of mathematical analysis it is known that the function f x is possible to approximate on the basis of
Taylor expansion to the series by the polynomial of denite degree, that means to write this function using of differentials of
k
the form (6), where d f a; x is the differential of the k- place value of the function f x.

0 1 1 1 k
f x d f a; x d f a; x    d f a; x Rk x; 6
1! k!
If we neglect the function Rk x (approximation error) in the Eq. (6), we will get an approximate expression, i.e. the
approximation for this function in the form (7).

0 1 1 1 k
f x  d f a; x d f a; x    d f a; x: 7
1! k!
The nal model was created on the basis of related reections related to the possibility of approximation of the function
y f x by Taylors polynomial so that we regarded the members of the series (7) ending by the differential of the second series.
Forasmuch as our model is dependent on two variables, weight m and height h, it is possible to transform the function
y f x f m; h after modications in form (8).
2
y b0 b1  h b2  m b3  h b4  m2 b5  h  m: 8

The regression function (8) was supplanted by selective regression function (9).
2
Y b0 b1  h b2  m b3  h b4  m2 b5  h  m: 9

4. Results

4.1. Presentation of the results (practically)

We can determine from each measurement recording for example the actual size of forces in dependence on time, max-
imum values of the forces acting on the belt, duration of the shock. The maximum loading force is generated by the rst
impact of the drop hammer on the test specimen; next extreme forces (Fig. 4) are caused by reections and consequent im-
pacts of the drop hammer on the test specimen.
In the rst approximation we selected values of forces from the rst phase of drop hammer impact on the test specimen
from the le of measured data.
For the determination of forced needed for research in all next measurements we used maximum values of forces of the
rst phase of drop hammer impact on the test specimen. On this basis, in accordance with the statistical procedures related
36 G. Fedorko et al. / Engineering Failure Analysis 36 (2014) 3038

Fig. 6. Compare of tension forces values obtained experimentally and by calculation using the model (11).

Table 2
Maximum values of the tension force Fs [kN] depending on the weight m and shatter height h.

m[kg]/h[m] 50 60 70 80 90 100
0.2 36.670 38.220 40.064 41.712 42.232 44.116
0.4 40.260 42.124 44.204 46.225 47.363 50.002
0.6 43.615 45.391 47.677 50.286 52.582 54.053
0.8 45.666 47.618 50.620 52.591 56.653 58.909
1.0 48.167 50.463 53.710 57.644 59.635 62.519
1.2 50.100 53.523 56.702 60.312 62.970 64.736
1.4 52.317 56.192 60.214 63.510 67.179 70.534
1.6 54.740 58.948 62.578 66.198 69.416 72.672
1.8 56.221 61.234 64.942 69.945 71.937 73.085
2.0 58.507 63.147 67.199 71.701 74.458 79.432
2.2 58.379 65.609 68.405 74.850 76.871 82.335
2.4 61.832 66.590 71.073 73.938 81.080 84.670
2.6 63.353 69.474 74.115 83.120 84.739

to the suitability of the data selection from the basic set it was created the Table 1 with maximum values of shock force, then
regression function (9) for shock force is (10) and to this the calculated index of determination which presents the suitability
of the found model is I = 0.9988.

2
F i 0:3859 2:0998  h 0:0081  m  0:8029  h  3:3556  m2 0:1089  h  m 10

Analogously it was also determined the regression function for tension force (11) with an index of determination I = 0.9959.

2
F s 19:9463 11:1003  h 0:3122  m  2:2634  h  0:0011  m2 0:1262  h  m 11

The Fig. 5 graphically presents the tightness of shock forces values obtained experimentally (Table 1) and values of
shock forces obtained by calculation using the model (10). Anomalies among experimental and calculated values are very
small, some as insignicant. The Fig. 6 presents the tightness of tension force values obtained experimentally (Table 2)
and tension force values obtained by calculation using the model (11). Analogous to the case of shock force, also in the case
of tension force, anomalies among experimental and calculated values are very small. In both cases it is presented and con-
rmed the suitability of obtained models.

Fig. 7. Analyzed test specimen with created depression on the bottom side.
 G. Fedorko et al. / Engineering Failure Analysis 36 (2014) 3038 37

4.2. Analysis of the conveyor belt sample

During the measurement it began to create an oval bulge (Fig. 7) on the bottom side of the test specimen (bottom cover
layer of the test specimen). We did not regard signicant changes in the substructure of the top cover layer after the rst
three impacts at the point of test impactor impact on the topside of the analyzed test specimen. We regarded small cracks
during next impacts of the impactor.
After completion of the experimental measurements the test specimen was submitted to nal visual control for damages
formation. Its result was the statement that the analyzed test specimen was not damaged by breakdown (it was not syn-
chronic breakdown of the top and bottom cover layer of the test specimen). By visual control it was observed just cracks
in the top cover layer and the above-mentioned formation of local oval bulge.
But the existence of this bulge predicted that there were some changes by the test in the internal structure of the test
specimen.

5. Conclusions

Damage of the conveyor belt by breakdown is often case that occurs in continuous transport of sharp-edged materials. If
we want to identify the conveyor belt as breakdown, it must be satisfy the conditions of simultaneous damage of all struc-
tural layers of the conveyor belt, and the destructive line runs steady through its top and bottom cover layer.
Based on this denition, we can state that there was not damage of the test specimen by breakdown during realized
experiments on the test device. From the measured data we created mathematicalstatistical models describing the depen-
dence of the shock or tension force on the weight and shatter height (10) and (11). These models show very good results
(Figs. 5 and 6).
These models enable to recalculate the sizes of the shock or tension force for arbitrary values of weights and heights by
use of interpolation. We can collect these values for the weight from the interval between minimal and maximal weight of
the drop hammer and for the height from the interval between minimal and maximal shatter height used by experiments.
Determination of the boundary value of the impact energy, by which it comes to the breakdown, so damage of the con-
veyor belt, has a practical relevance for users. A user can set the shatter height and maximum weight of the falling weight at
the point of shifting right in operation, so that it does not make, or exceed the size of end-point impact energy.
Despite of the statement that the test specimen was not damage by breakdowns during the test, it was identied a local
anomaly on the test specimen which was at the point of simulated place of sharp-edged material impact.

Acknowledgements

This work is a part of research project VEGA 1/0922/12 Research of effect of material characteristics and technological
parameters of conveyor belts on size of contact forces and resistance to motion in pipe conveyors with experimental and
simulation methods.
This work is a part of research project VEGA 1/0085/12 New strategy for effective measurements with coordinate mea-
suring machines with multi sensor systems.

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