Application of Abrasion Depending Life Cycle and Optimal
Application of Abrasion Depending Life Cycle and Optimal Maintenance Strategies for Belt Conveyor Systems • Introduction and problem formulation • Information system for belt conveyor systems • Determining of strain parameters • Application and conclusion Advanced Process Control Applications for Industry Workshop May 2005 M. Sader*, R. Noack*, P. Zhang**, E. Stein*, S. X. Ding** * University of Applied Sciences Lausitz, Senftenberg, Germany ** University of Duisburg-Essen, Germany
Introduction - belt conveyor in an open mine Lausitz / Germany • operation and environmental conditions (temperature, rain, frost, dust) • multiple stress (geometric structure, load) • complex mechanical and electrical systems • up to 40. 000 t/h • several kilometres 2
Problem formulation - fault detection • devices require a high level of availability and safety mass flow idlers reverse pulley • on-line monitoring and detection of extraordinary system states / faults • identifying the operation parameters aiming at state based and abrasion depending maintenance belt sensor • optimal operating efficiency gear drive pulley 3
Problem formulation - maintenance basic-strategies of maintenance damage-based primary focus damage-elimination time-based condition-based primary focus damage-prevention • operation until breakdown • controllable maintenance • risk consequential damage • change before breakdown • high storage costs • high staff costs • maintenance initiation after forecasted strain • maintenance initiation after real abrasion 4
Information system for belt conveyor systems - overview - 5
Information system for belt conveyor systems - model Belt conveyor system Residual generator Observer - Residual evaluation Postfilter Input Thres. Norm based Decision hold Evaluation function logic Faults FAR Estimated output Residuals Measured output Information system 6
Information system for belt conveyor systems - research objectives robust observer design FDI applications I. fault free II. fault III. fault free with disturbance r r r FDI with consideration of the FAR 100% 0% 7
Information system for belt conveyor systems - research objectives Ideas and approaches: • using existing methods to calculation of active damage with more data from the model • interpretation of the results of FAR for maintenance • online estimation of the active friction -> conclusion of the active damage 8
Determining of strain parameters - definition damage contribution an remaining life time discrete damage contribution Sk Sp forecasted strain Lp forecasted life cycle Lk life cycle of the real components strain cumulative damage contribution Sges load-depending remaining life time N 9
Determining of strain parameters - relevant components of a belt conveyor - • • • idlers belt gear drive pulley 10 reverse pulley
Determining of strain parameters - example idler nominal life cycle L 10 of ball bearings dynamic equivalent radial load Pr 11
Determining of strain parameters - Problem mass distribution - model based solution- 12
Determining of strain parameters - analysis with measured data of an open-mining coal belt conveyor - - length of more than 1000 meter - more than 800 idlers 13
Determining of strain parameters - analysis with measured data of an open-mining coal belt conveyor - 14
Conclusion The application results presented above demonstrate that : • abrasion depending life cycle to optimize the preventive maintenance strategies • the advantage of the dynamic condition based calculation method is shown • problem: start damage contribution not given Outlook : • • methods verification by long running test on belt conveyor systems determining of the minimum of remaining life cycle industrial application on belt conveyor components expansion for other components of belt conveyor or other mining equipment 15
- Slides: 15