Plant Engineering benefits from Simulation Software

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The ever higher outputs of conveyor systems, especially in mining applications increase the need for detailed information on start-up behaviour during the project stage. With the simulation tool Turbosim, engineers can evaluate complete drive trains with hydrodynamic couplings to achieve higher planning safety and reduce operating risks.
Conveyor systems in mining applications are reaching higher and higher outputs. On the one hand, this makes increasing demands on materials and functionality, on the other hand, plant engineers request detailed information on the anticipated start-up behaviour already during the project stage. Voith Turbosim is a simulation tool for the evaluation of drive trains with hydrodynamic couplings. This applies
Overland belt conveyor with hydrodynamic couplings in the drive trains.

especially to belt conveyors. Voith Turbosim simulates the actual operating torque and consequently serves as a

basis for dynamic plant calculations. The software program allows the computer-supported design of fluid couplings, provides higher planning safety, reduces operating risks, and helps with the evaluation of output reserves. In order to minimize risks that might occur during the design and commissioning phase, computer programs for the evaluation of critical operating conditions of belt conveyor systems are becoming increasingly popular. If belt tensioning forces, the lift-off of the belt, belt slip, or voltage drops can be evaluated already during the project stage, the risk of a later operating failure is much reduced. The increasing output rates of conveyor systems also affect the drive system; after all, the start-up procedure plays an important role for the load on the belt. Here, the torque characteristics of the fluid coupling are a key factor. They decide the start-up behaviour of the driven machine and hence ensure that belt conveyors start smoothly.
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THE ENTIRE OPERATING PROCEDURECAN BE SIMULATED The introduction of torque to the belt via the hydrodynamic coupling can be optimised by demand-oriented curve characteristics. But the characteristic curves of hydrodynamic couplings cannot be calculated mathematically.

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Plant Engineering benefits from Simulation Software

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The calculation program Turbosim therefore has a comprehensive database of the characteristic curves of constant-fill couplings collected during empiric studies in test series. These curves focus, for example, on start-up times, the possible number of subsequent start-ups and the behaviour of the motors. As these characteristic curves are processed directly, plant engineers receive near-realistic representations. Once these limitations have been taken into account, the start-up procedure can be simulated. The simulation covers the entire operating process. The program consists essentially of two elements. The first element is used for the automatic pre-selection of a coupling type on the basis of fixed criteria. For this purpose, the plant operator provides the central performance data of the system (speed, load collective, motor output, and mass inertia). With this data, Turbosim can compile an overview of possible coupling types that would be suitable for this application. Customer requirements, such as torque limitation, ambient conditions, and frequency of start-ups are then added, in order to narrow down the selection even further. With the second element, start-up procedures of Voith fluid couplings for all kinds of plants and load collectives, for example single or multi-motor drives, as well as all operating conditions (start-up, nominal operation, shut-down, and special applications such as creep speed for inspection runs) can be simulated. The results from these simulations can provide valuable insight, especially when evaluating output reserves. ASSESSABLE PROGRAM RESULTS LEAD TO COST OPTIMIZATION These early-stage evaluations offer project engineers more scope for deciding which drive is the most suited. They increase planning safety, from projecting to commissioning and operation. They also show possible effects on the functionality of the entire system. Here, the program resorts to the database containing product details from case studies and test series. The processing of these data sets during the project stage allows secure statements regarding the anticipated operating conditions of the fluid coupling in the drive train. With the help of Turbosim, plant engineers receive realistic characteristic curves of the fluid coupling for plant calculations namely torque values that might occur at any time in dependence on the speed of the belt conveyor. On the basis of assessable program results, the introduction of power into the belt, as well as other plant components, can be optimised with Turbosim, resulting in possible cost optimisation. Helmuth Fleuchaus, Voith Turbo, Germany Copyright 2010 - Vogel Business Media

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