1、December 2011DEUTSCHE NORMNormenausschuss Bergbau (FABERG) im DINDIN-SprachendienstEnglish price group 21No part of this translation may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale
2、for German Standards (DIN-Normen).ICS 53.040.20!$Sa“1914862www.din.deDDIN 22101Continuous conveyors Belt conveyors for loose bulk materials Basis for calculation and dimensioning,English translation of DIN 22101:2011-12Stetigfrderer Gurtfrderer fr Schttgter Grundlagen fr die Berechnung und Auslegung
3、,Englische bersetzung von DIN 22101:2011-12Engins de manutention continue Transporteurs bandes pour produits en vrac Principes de base pour le calcul et la conception,Traduction anglaise de DIN 22101:2011-12SupersedesDIN 22101:2002-08www.beuth.deDocument comprises 56 pages05.13 DIN 22101:2011-12 2 A
4、 comma is used as the decimal marker. Contents Page Foreword . 4 1 Scope . 5 2 Normative references . 5 3 Terms and definitions 6 4 Symbols and units 7 5 Volume flow and mass flow . 12 6 Resistance to motion and required power for the steady operating condition . 14 6.1 General . 14 6.2 Primary resi
5、stances 15 6.2.1 General . 15 6.2.2 Determination of primary resistance . 15 6.2.3 Determination of the hypothetical friction coefficient 16 6.3 Secondary resistances . 17 6.3.1 General . 17 6.3.2 Determination of individual secondary resistances . 18 6.3.3 Approximate calculation of secondary resis
6、tances 19 6.4 Gradient resistance 20 6.5 Special resistances 20 6.5.1 General . 20 6.5.2 Determination of individual special resistances . 20 7 Design and layout of the drive system . 21 7.1 General . 21 7.2 Location of the drive units, size and number of drive motors . 22 7.2.1 General . 22 7.2.2 H
7、orizontal and slightly inclined installations 22 7.2.3 Uphill conveying installations . 23 7.2.4 Downhill conveying installations 23 7.2.5 Installations with uphill and downhill sections . 23 7.3 Starting, stopping and holding 23 7.3.1 Starting 23 7.3.2 Stopping and holding . 24 8 Belt tensions and
8、take-up forces 25 8.1 General . 25 8.2 Required belt tensions . 25 8.2.1 General . 25 8.2.2 Minimum belt tensions required for the transmission of pulley peripheral forces . 25 8.2.3 Minimum belt tensions required for the limitation of the belt sag and for correct belt guiding . 27 8.3 Local belt te
9、nsion variations in the top and return strands . 27 8.3.1 General . 27 8.3.2 Steady operating condition . 28 8.3.3 Non-steady operating condition 28 8.4 Take-up forces and take-up distances . 29 8.5 Local belt tensions in the upper and lower strands 31 8.5.1 General . 31 8.5.2 Non-steady operating c
10、onditions 31 8.5.3 Steady operating condition . 31 FHDIN 22101:2011-12 3 9 Distribution of belt tensions across the belt width 31 9.1 General . 31 9.2 Transition curves . 32 9.2.1 General . 32 9.2.2 Distribution of the belt tension for textile conveyor belts 34 9.2.3 Distribution of the belt tension
11、 for steel cord conveyor belts 34 9.3 Curves. 35 9.3.1 Horizontal curves 35 9.3.2 Vertical curves . 35 10 Design and layout of the conveyor belt 37 10.1 General . 37 10.2 Design and layout of the tension member 37 10.3 Design and layout of cover layers . 40 11 Minimum pulley diameter . 41 12 Design
12、and layout of transition curves and vertical curve radii. 42 12.1 General . 42 12.2 Determination of the minimum transition length . 43 12.2.1 General . 43 12.2.2 Conveyor belts with textile plies 43 12.2.3 Steel cord conveyor belts . 43 12.3 Determination of the minimum radius of vertical curves 44
13、 12.3.1 General . 44 12.3.2 Convex curves . 44 12.3.3 Concave curves . 44 13 Dimensioning of belt turnovers . 44 Annex A (informative) Explanatory notes 46 Annex B (informative) Explanations of relationship of this standard to international standards 53 Bibliography 55 DIN 22101:2011-12 4 Foreword T
14、his standard has been prepared by Working Committee Frdergurte (Conveyor Belts) of the Normenaus-schuss Bergbau (FABERG) (Mining Standards Committee). Annexes A and B are provided for information and are informative. This standard relates to the standards ISO 5048:1989, ISO/DIS 3870:1996, ISO 5293:1
15、981 and ISO 3684:1990 issued by the International Organization for Standardization (ISO) (see Annex B). Amendments This standard differs from DIN 22101:2002-08 as follows: a) the method for calculating motion resistances has been extended to cover belt conveyors where the number of sections relevant
16、 for the calculation varies for the top and bottom strands; b) the start-up factor pAand braking factor pB are now defined; d) in the clause on the design and layout of the conveyor belt a factor has been introduced to account for an irregular distribution of belt tension across the belt width; e) i
17、nformation on calculating the pulley load factor has been added in Clause “Minimum pulley diameter”; f) Clause “Determination of the minimum transition length” has been completely revised; g) normative references have been updated; h) the standard has been editorially revised. Previous editions DIN
18、BERG 2101 Part 1: 1933-07 DIN BERG 2101 Part 2: 1933-07 DIN BERG 2101 Part 3: 1933-07 DIN 22101: 1942-02, 1982-02, 2002-08 c) the clause “transition curves” has been condensed by combining the theoretical principles common to textile and steel cord belts; DIN 22101:2011-12 5 1 Scope This standard is
19、 applicable to belt conveyor installations for conveying bulk materials, and contains the principles relating to their design. The standard makes it possible to specify essential requirements applicable to major belt conveyor components such as drives, brakes and take-up devices for particular conve
20、ying conditions. The standard also gives a description of the design and dimensioning of the conveyor belt. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references,
21、the latest edition of the referenced document (including any amendments) applies. DIN 15207-1, Continuous mechanical handling equipment Idlers for belt conveyors Main dimensions of idlers for belt conveyors for bulk material DIN 22102-1, Conveyor belts with textile plies for bulk goods Part 1: Dimen
22、sions, specifications, marking DIN 22102-3, Conveyor belts with textile plies for bulk goods Part 3: Permanent joints DIN 22107, Continuous mechanical handling equipment Idler sets for belt conveyors for loose bulk materials Principal dimensions DIN 22109-1, Conveyor belts with textile plies for coa
23、l mining Part 1: Monoply belts for underground applications Dimensions, requirements DIN 22109-2, Conveyor belts with textile plies for coal mining Part 2: Rubber-belts with two plies for underground applications Dimensions, requirements DIN 22109-4, Conveyor belts with textile plies for coal mining
24、 Part 4: Rubber-belts with two plies for above ground applications Dimensions, requirements DIN 22110-3, Testing methods for conveyor belt joints Part 3: Determination of time strength for conveyor belt joints (dynamical testing method) DIN 22112-1, Belt conveyors for underground coal mining Idlers
25、Part 1: Dimensions DIN 22112-2, Belt conveyors for underground coal mining Idlers Part 2: Requirements DIN 22121, Conveyor belts with textile plies for coal mining Permanent joints for belts with one or two plies Dimensions, requirements, marking DIN 22129-1, Steel cord conveyor belts for undergroun
26、d coal mining Dimensions, requirements DIN 22129-4, Steel cord conveyor belts for use in underground coal mining Belt joints Dimensions, requirements DIN EN 15236-11) Steel cord conveyor belts Part 1: Design, dimensions and mechanical requirements for conveyor belts for general use ISO 3684:1990-3,
27、Conveyor belts Determination of minimum pulley diameters 1) Translators note. The German original is incorrect. The standard number should read “DIN EN ISO 15236-1”. DIN 22101:2011-12 6 3 Terms and definitions For the purposes of this document, the following term and definition apply. 3.1 belt conve
28、yor continuous belt conveyor for bulk materials with circulating conveyor belts which feature tension members of textile or steel cord ply and cover layers of rubber or plastic supported on carrying idlers and idler stations, and driven or braked by friction grip via pulleys and driving belts where
29、appropriate 1) Translators note. The German original is incorrect. The standard number should read “DIN EN ISO 15236-1”. NOTE Conveyor belts with cover plates made of rubber or plastic are described e.g. in DIN 22102-1, DIN 22109-1, DIN 22109-2, DIN 22109-4, DIN 22129-1 and DIN EN 15236-11). Idlers
30、and idler sets are described e.g. in DIN 15207-1, DIN 22107, DIN 22112-1 und DIN 22112-2. DIN 22101:2011-12 7 4 Symbols and units Table 1 Symbols and units Symbol Meaning Unit A Cross section of fill m2A1Partial cross section above water fill m2(mm2)aA2Partial cross section with = 0 (water fill) AGr
31、Effective contact area between cleaner and belt mm2B Belt width mm C Coefficient for the approximate calculation of total secondary resistance DTrPulley diameter mm ELGkElasticity module related to the width of the belt N/mm FaForces resulting from acceleration/deceleration under non-steady operatin
32、g conditions N FAufInertia resistance of material conveyed and frictional resistance between material conveyed and belt at the feeding point N FEIndentation rolling resistance: Sum of all indentation rolling resistances in the upper and/or lower strands N FE,3Indentation rolling resistance for a 3-r
33、oller idler set N FEIndentation rolling resistance related to the belt width N/m FGaResistances of material transfer devices arranged along the belt conveyor path N FGrFriction resistance caused by belt cleaners N FHPrimary resistance: Sum of all primary resistances in the upper and/or lower strands
34、 N FM,vVertical force related to the belt width N/mm FnNormal force acting on an idler N FNSecondary resistance: Sum of all secondary resistances in the upper and/or lower strands N FRRunning resistance of idlers: Sum of all running resistances in the upper and/or lower strands N FRstCamber resistan
35、ce: Sum of all camber resistances for an idler set N FSSpecial resistance: Sum of all special resistances in the upper and/or lower strands N FSchFriction resistance between material conveyed and lateral chutes outside the acceleration zone of feeding points N m2(mm2)aDIN 22101:2011-12 8 Table 1 (co
36、ntinued) Symbol Meaning Unit FSchbFriction resistance between material conveyed and lateral chutes within the acceleration zone of a feeding point N FSpTake-up force at the axis of the take-up pulley N FStGradient resistance: Sum of all gradient resistances in the upper and/or lower strands N FTLoca
37、l belt tension (strand tension) N FTmMean belt tension of upper strand and lower strand N FTrTotal pulley peripheral force N FT1Belt tension (strand tension) of the belt running onto a pulley N FT2Belt tension (strand tension) of the belt running off a pulley N FWMotion resistance: Sum of all resist
38、ances to motion in the upper and/or lower strands N ImMass flow kg/s Im,NNominal mass flow kg/s IVVolume flow m3/s IV,NNominal volume flow m3/s L Distance axis-to-axis m PMTotal power of drive motors kW PM,NNominal drive motor capacity kW PWTotal power at the periphery of the driving pulley(s) requi
39、red due to the motion resistances in steady operation kW RaRadius of a concave vertical transition curve m (mm)aReRadius of convex vertical transition curve m (mm)aS Safety factor related to the nominal breaking strength of the belt S0Safety factor taking belt splice manufacturing characteristics in
40、to consideration S1Safety factor taking into consideration expected belt life and operational stresses on belt SminMinimum value for the safety factor, related to the minimum nominal breaking strength of the belt Acceleration or deceleration m/s2b Usable belt width mm bRLength of the contact line be
41、tween belt and idler face m bSPart of belt lying on a side idler (only for 2- or 3-roller idler sets) mm bSchClear width between chutes m caFactor used in the numerical equation describing the indentation rolling resistance determined in relation to the belt width cbExponent used in the numerical eq
42、uation describing the indentation rolling resistance determined in relation to the belt width DIN 22101:2011-12 9 Table 1 (continued) Symbol Meaning Unit cKCoefficient for determination of the minimum dynamic splice efficiency corresponding to the width related belt tension in the belt edges cRCoeff
43、icient for calculating the masses of the idlers reduced to their periphery cRankRankine factor cRstCoefficient for the calculation of camber resistance cSchbCoefficient for taking into account additional resistance between material conveyed and lateral chutes in the feeding zones caused by dynamic p
44、ressure of the mass flow fed in cTrCoefficient for the determination of the minimum pulley diameter cCoefficient for the determination of the standard value for the minimum transition length dGkThickness of the load-bearing longitudinal tension member (without outer warp layer or weft, for example)
45、mm e Base of natural logarithms (e = 2,718 28.) eKDistance from the centre line of belt plies at the edge of the belt to the neutral axis of the belt mm eMDistance from the centre line of belt plies at the centre of the belt to the neutral axis of the belt mm f Hypothetical friction coefficient for
46、the approximate calculation of the total primary resistance to motion of the upper and lower strands fiHypothetical friction coefficient for the approximate calculation of the primary resistance of a section of the upper or lower strand g Acceleration due to gravity (g = 9,81 m/s2) m/s2h Height diff
47、erence of a section of the upper or lower strand (h 0 for uphill belt travel, h 0 for uphill belt travel, 2 000mm b = B 250 mm (2) The usable belt width of belt conveyors with horizontal curves and inclined idlers installed to stabilize the belt may be smaller. With 1-, 2- and 3-roller idler sets in
48、 horizontal belt conveyors, the theoretical cross section of fill Aththat is equivalent to the real cross section of fill can be established using angle as the sum of partial cross sections A1,thand A2,th (see 1, Figure 1 and Annex A): ( ) 4tancos2MMth1, += lblA (3) sin2cos2MMMth,2+=lblblA (4) The s
49、election of an equivalent slope angle depends on the material to be conveyed as well as on the length of the conveying distance. In case of lacking experience in selecting an adequate slope angle, the following standard values can be applied: The value will be = 20 for materials with normal flow properties. Values below = 20 down to = 0 will be characteristic for nea
