JOURNAL OF CHINA UNIVERSITY OF

MINING &
TECHNOLOGY
J China Univ Mining & Technol 18 (2008) 0459–0465
www.elsevier.com/locate/jcumt

Mechanism of hydro-viscous soft start of

belt conveyor
MENG Qing-rui, HOU You-fu
School of Mechanical and Electrical Engineering, China University of Mining & Technology, Xuzhou, Jiangsu 221008, China

Abstract: The mechanism of a hydro-viscous soft start is of great importance in the design of a hydro-viscous clutch and its control
system. To explain the mechanism of a hydro-viscous soft start, the startup process of a belt conveyor was numerically analyzed
with the modified Reynolds equation, an energy equation and a temperature-viscosity equation. The effect of temperature and
grooves of the friction disk surface on torque transfer and load capacity of the oil film have also been analyzed. The results show
that 1) the grooves are the basis of forming dynamic pressure but they may reduce the capacity of torque transfer to a certain extent,
2) during the startup process, temperature has little effect on torque transfer and load capacity and the variation in load capacity of
the oil film is very small, indicating that it is preferable to use the flow rate as a control object than the pressure of the feed cylinder.
The results have been verified by an experiment.
Key words: hydro-viscous clutch; soft start; belt conveyor; torque transfer; load capacity

1 Introduction tion. Many studies on engagement have been carried

Belt conveyors are in many cases the most
cost-effective solution for handling bulk material in
mass flows over short and medium conveying dis-
tances. With great inertia and a short starting time, the
acceleration at the start will be very great, considera-
bly affecting the tight side of conveyor belt, if the
startup process of the belt conveyor is not properly
controlled. As a result, the dynamic stress induced by
this effect is increased several times, compared with
normal operation. To ensure reliable operation, the
strength grade of the belt should be increased. Thus
the prophase investment will be greatly increased.
The soft starter is a perfect solution for this problem
because it can reduce total investment by 20%. A hy-
dro-viscous soft starter has a good application pros-
pect among the soft starters commonly used at pre-
sent, because its performance is superior to electrical
soft starters at low speed and superior to hydraulic
coupling at high speed.
A hydro-viscous soft starter (hydro-viscous clutch)
is similar in structure to a wet clutch. It is based on
Newton's Law of Viscosity and transfers power by the
shearing force of an oil film. According to the
Stribeck curve, the engagement of the hydro-viscous
clutch can be divided into three stages: hydrodynamic
lubrication, mixed lubrication and boundary lubrica-
out up to the present[1–10]. But all of the previous
studies largely concentrated on speed regulating
characteristics of the hydro-viscous clutch, or just on
the engagement of a wet clutch. The main issues are
as follows: investigating the relationship between
normal pressure, output speed and torque under the
condition of a given oil film thickness, or investigat-
ing the relationship between the oil film thickness,
output speed and torque under the condition of nor-
mal pressure. Few studies on characteristics of hy-
dro-viscous soft starters have been carried out. Unlike
speed regulation for fans or water pumps, differences
in both oil film thickness and rotational speed are in
dynamic development during the entire startup proc-
ess. At the initial time of the startup, the rotational
speed difference is large and the oil film is thick,
while at the end of the startup process, the oil film is
thin and the rotational speed difference is small. In
addition, the load capacity of the oil film is also de-
veloping dynamically. Obviously, it is not a good
way to investigate the soft start process under these
conditions of oil film thickness or normal pressure.
Because the pressure of the feed cylinder should
change dynamically and to counterbalance the dy-
namically changing load capacity of the oil film to
obtain different oil film thicknesses at different times,
torque transfer and load capacity of the oil film are

Received 15 February 2008; accepted 12 April 2008

Corresponding author. Tel: +86-516-83890238; E-mail address: bigblenny2000@sina.com
460 Journal of China University of Mining & Technology Vol.18 No.3

two key parameters affecting the characteristics of a
hydro-viscous soft start.
Considering the surface roughness of the friction
disc, we have investigated numerically and analyti-
cally the load capacity and torque transfer character-
istics of the oil film during the startup process by us-
ing a Reynolds equation, an energy equation and a
temperature-viscosity equation in order to reveal the
mechanism of the hydro-viscous soft start of the belt
conveyor and to facilitate the conceptual design of the
hydro-viscous soft starter and the control system.
hydro-viscous soft start by using a Cartesian coordi-
nate system, since the friction discs have different
surface grooves. The friction disc used by us has ra-
dial surface grooves. For convenience, only a part of
the friction disc, including three grooves, is analyzed
(see Fig. 2), where AD is the inlet and BC is outlet of
the flow domain.

2 Soft start

A soft start means that a belt conveyor can

smoothly start by progressively overcoming the iner-
Fig. 2 Calculation model
tia even under the condition of a full load. In order to
reduce the damage of the impact, there should be no Since the load capacity of the oil film in a hy-
sudden change in acceleration. So during a perfect dro-viscous clutch is much less than that in a hydro-
startup process the speed should vary from zero to the dynamic lubrication bearing, the radial flow induced
rating value according to a given starting curve. Both by the centrifugal force plays an important role and
the Harrision and Nordell curves are commonly used cannot be neglected, Reynolds equation is modified
as starting curves and are shown in Fig. 1, where V is by the effect of the centrifugal force in our calcula-
the rated speed and Ts starting time. The Harrision tion model. In our Cartesian coordinate system, the
curve is more popular and is used by us to investigate xoy plane represents the friction disc surface and the
the characteristics of a soft start[11]. oil film thickness is represented along the z direction.
Considering the friction disc surface roughness and
by using a Patir-Cheng average flow model, the
modified Reynolds equation can be derived as fol-
lows:
∂ ⎛ h3 ∂ p ⎞ ∂ ⎛ h3 ∂p⎞
⎜ φx ⎟+ ⎜ φy ⎟
∂x ⎝ 12µ ∂x ⎠ ∂y ⎝ 12 µ ∂y ⎠
(a) Harrision curve (b) Nordell curve
Fig. 1 Harrison and Nordell starting curves U − U 2 x ∂ h T U1 y − U 2 y ∂ h T
= 1x +
2 ∂x 2 ∂y
The torque transferred by the oil film between fric-
U − U 2 x ∂φs U1 y − U 2 y ∂φs
tion discs can be calculated. By definition: + 1x σ + σ
2 ∂x 2 ∂y
M = πµ (ω1 − ω2 ) ( r24 − r14 )
1 1
(1)
∂ ⎡ ρ xhT 3 2 ⎞⎤
3
2 h ⎛
+ ⎢ ⎜ ω1ω 2 + ω1− 2 ⎟ ⎥
where M is torque transferred by oil film, µ dy- ∂x ⎢ 12 µ ⎝ 10 ⎠ ⎥⎦
⎣
namic viscosity, ω1 and ω 2 are input speed and
∂ ⎡ ρ yhT ⎛ 3 2 ⎞⎤
3
output speed respectively, h is oil film thickness, + ⎢ ⎜ ω1ω2 + ω1− 2 ⎟ ⎥ (2)
r1 and r2 are the inner and outer radius of the fric- ∂y ⎢ 12µ ⎝ 10 ⎠ ⎥⎦
⎣
tion discs respectively.
It can be seen from Fig. 1a and Eq.(1) that the cor- where φx and φ y are pressure flow factors along
responding speed, acceleration and oil film thickness the x and y direction respectively and φs is the shear
at any moment can be calculated and these results
flow factor. U ix , U iy (i = 1, 2) are the components of
provide the basic data for further calculation of load
capacity and torque transfer of the oil film at any velocity of the friction disc along the x and y direction.
moment during the startup process. hT = h + δ1 + δ 2 is the real oil film thickness, h is
the nominal oil film thickness, i.e., the distance be-
3 Fundamental equations tween the two “middle surfaces”, one the rough sur-
face of the friction disc and the other of the separator,
3.1 Modified Reynolds equation δ1 and δ 2 are the surface roughness by taking each
It is preferable to investigate the characteristics of a “middle surface” as reference respectively. h T is
MENG Qing-rui et al Mechanism of hydro-viscous soft start of belt conveyor 461

the average oil film thickness and the mathematical ⎡ 1 ∂p ⎛1 2 1 ⎞⎤

τx = h⎢ − ρ x ⎜ ω12 − ω1ω1− 2 + ω12− 2 ⎟ ⎥
expectation of hT . Without the rough contact, h is ⎣ 2 ∂x ⎝2 3 4 ⎠⎦
equal to h T , otherwise h ≠ h T . p is the average µ
− (U1x − U 2 x ) (9)
oil film pressure, ω1− 2 = ω1 − ω2 and ρ is density of h

the lubricating oil. ⎡ 1 ∂p ⎛1 2 1 ⎞⎤

τy = h⎢ − ρ y ⎜ ω12 − ω1ω1− 2 + ω12− 2 ⎟ ⎥
Boundary conditions: ⎣ 2 ∂y ⎝2 3 4 ⎠⎦
p | AD , BC = p0 µ
JG
(3) −
h
(U 1y − U2y ) (10)
G ⎛ hU h3 ⎞
n ⎜⎜ − ∇p ⎟⎟ = q on AB and CD (4) Torque (M) can be calculated as:
⎝ 2 12 µ ⎠
Inlet pressure on AD is at 0.1–0.5 MPa and the M = ∫∫ (τ x y + τ y x )dxdy (11)
outlet pressure on BC is 0 MPa. The boundary condi-
tion on AB and CD is a flowrate boundary condition, The oil film load capacity can be calculated by the
representing influent and effluent flows respectively. following equation:

3.2 Energy equation W = ∫ pdΩ = ∫∫ pdxdy (12)

Ω
The oil film temperature is essentially caused by
convection and heat conduction is a form of secon-
4 Calculation methods
dary heat transfer. It indicates that the heat flux on the
fluid boundary is very small and temperature and
We have used a finite element method to solve the
viscosity along the oil film thickness direction can be
modified Reynolds equation and the energy equation.
treated as constants[12] so that oil film energy equation
In order to approach the sophisticated friction disc
is:
surface, a triangular element with three nodes is se-
⎛ ∂T ∂T ⎞ lected and pressure of the element is built into a linear
ρ Cv ⎜ q x + qy ⎟
⎝ ∂x ∂y ⎠ model as follows:
µ ⎡ p = a + bx + cy (13)
( ) ( ) ⎤
2 2
= ⎢ U − U + U − U ⎥
hT ⎣ ⎦
1 x 2 x 1 y 2 y
Assuming the three vertices of an element are
h T ⎡⎛ ∂ p ⎞ ⎛ ∂ p ⎞ ⎤
3 2 2
( xi , yi ) , ( x j , y j ) and ( xm , ym ) , then the follow-
+ ⎢⎜ ⎟ +⎜ ⎟ ⎥ (5)
12µ ⎢⎝ ∂x ⎠ ⎝ ∂y ⎠ ⎥ ing coefficients can be calculated:
⎣ ⎦
where qx and q y are average flows of the lubri- ai = x j ym − xm y j , a j = xm yi − xi ym ,
cating oil. am = xi y j − x j yi , bi = y j − ym ,
Boundary conditions:
T | AD , BC = T0 (6) b j = ym − yi , bm = yi − y j , ci = xm − x j ,

∂T c j = xi − xm , cm = x j − xi .
=0 on AB and CD (7) The interpolation function is as follows:
∂n 1
3.3 Temperature-viscosity equation
Ni = ( ai + bi x + ci y ) ( i = i, j , m ) (14)
2A
Without a universal temperature-viscosity equation, where A is the area of the triangular element.
we have used an ASTM line graph. The equation is as The form of the function used in solving the modi-
follows: fied Reynolds equation is as follows[13]:
JG
log log (η + 0.6 ) = A − B log T (8) ⎡⎛ h 3 hU ⎞
I ( p ) = ∫ ⎢⎜⎜ ∇p − ⎟ ∇p
where η is kinematic viscosity (mm /s), A and B are
2 Ω
⎢⎣⎝ 24 µ 2 ⎠⎟
two constants which can be calculated from the vis- ∂h ⎤
+ p dΩ + ∫ qpds (15)
∂t ⎥⎦
cosity at two different temperatures. Γ2

3.4 Torque transfer and load capacity where Γ 2 represent AB and CD as shown in Fig. 2.
Shear stress along the x and y directions can be The functional of modified Reynolds equation can be
calculated by the following equations: derived from Eq.(15). If the jm edge of the triangular
element lies on Γ 2 , p can be calculated by the
462 Journal of China University of Mining & Technology
following equation:
p = (1 − ξ ) p j + ξ pm ( 0 < ξ < 1 )
The Galerkin approach is used to solve the en-
ergy equation as follows:
⎛ ∂T ∂T ⎞
∫Ω Ni ρCV ⎜⎝ q x ∂x + q y ∂y ⎠⎟ dΩ
⎧µ
= ∫ N i ⎨ ⎡⎢(U1x − U 2 x ) + (U1 y − U 2 y ) ⎤⎥
2 2
Ω
⎩ hT ⎣ ⎦ Rated speed v (m/s)
h T ⎡⎛ ∂p ⎞ ⎛ ∂p ⎞ ⎤ ⎫⎪
3 2 2
+ ⎢ ⎜ ⎟ + ⎜ ⎟ ⎥ ⎬ dΩ
12 µ ⎢⎣⎝ ∂x ⎠ ⎝ ∂y ⎠ ⎥⎦ ⎪
⎭ Fluid density ρ (kg/m3)
5 Calculation steps
1) Generating the finite element mesh. Finite ele-
ment mesh should be generated on grooves and
non-groove regions respectively.
2) At discrete intervals, repeat the startup process
according to rated load and speed, the corresponding
speed, acceleration and oil film thickness at each time
can be calculated by Eq.(1) and Fig. 1a.
3) Calculation of corresponding torque each time
by modified Reynolds equation. Modify the oil film
thickness calculated in step 2 from the calculation
results.
4) Temperature distribution. The initial temperature
can be assumed to be a constant, i.e., T = const.
5) According to Eq.(8) and definition µ = ηρ , the
calculated viscosity distribution µ = µ (T ) .
6) Calculate the node-pressure according to the
function of the modified Reynolds equation.
7) Calculate the node-temperature according to the
energy equation.
8) Compare the node-temperature calculated in
step 7 with the given temperature in step 4. A con-
vergent result can be obtained if the comparative re-
sult satisfies convergence criterion, otherwise substi-
tute the node temperature calculated in step 7 for
temperature distribution given in step 4 and recalcu-
late. The convergence criterion is as follows:
T ( k ) − T ( k − 1)
≤ 0.01
T (k )
where T(k) and T(k–1) are average temperature of
nodes calculated in step k and step k–1.
9) Calculate torque and load capacity.
6 Results and discussion
A hydro-viscous clutch of 75 kW is used as an
example to investigate the mechanism of a soft start.
The friction discs used in the hydro-viscous clutch
have 30 radial grooves distributed uniformly. Other
parameters are shown in Table 1.
Vol.18 No.3
Table 1 The input data in calculation
(16) Parameter Value
Input speed n1 (r/min) 1470
Starting time Ts (s) 40
Inner radius of friction disc r1 (m) 0.0575
Outer radius of friction disc r2 (m) 0.076
Width of groove Wd (m) 0.004
Depth of groove Wt (mm) 0.2
2
Friction disc surface roughness σ1 (µm) 4
Separator surface roughness σ2 (µm) 1
(17)
Fluid kinematic viscosity η (mm2/s) 32
865
Fluid specific heat capacity Cv (J/(g·ć)) 1.88
γ is a surface texture parameter. We have set
γ = 1 and the values of φx , φ y and φs are as fol-
lows: φx ˙0.8323, φ y ˙0.8323, φs ˙0.322.
Variations of oil film thickness during the startup
process, according to theoretical calculations, are
shown in Fig. 3.
Oil film thickness (mm)
Fig. 3 Variation of oil film thickness
It can be seen from Fig. 3 that oil film thickness is
too thick in the first five seconds and too thin in the
last five seconds of the startup process. The oil film
thickness is less than 10 µm and the hydro-viscous
clutch works in a mixed lubrication stage during the
last five seconds.
The torque transferred by oil film is rather small
when the oil film thickness is greater than 0.2 mm.
The gap between friction discs is usually designed to
be less than 0.4 mm. Furthermore, the hydro-viscous
clutch should overcome the static friction force of the
belt conveyor. At 35 s, the output speed is greater
than 1400 r/min, close to input speed. From this point
on, the torque begins to be transferred by both the oil
film and the rough surface of the friction disc. In this
period the hydro-viscous clutch cannot be controlled
well. Thus, our theoretical analysis is only suitable
for the period from five seconds to 35 seconds. A
closed-loop feedback control should be used in the
first five seconds and last five seconds in order to
approach the starting curve shown in Fig. 1a. In fact a
closed-loop feedback control is usually used during
the entire startup process to achieve a perfect starting
MENG Qing-rui et al Mechanism of hydro-viscous soft start of belt conveyor 463

curve. namic pressure is not so clear because the oil film is

It can also be seen that the hydro-viscous clutch
works at a hydrodynamic lubrication stage during
most of the startup process. Although a hydro-viscous
clutch works at a mixed lubrication stage during the
last five seconds, because the rotational speed differ-
ence is rather small and duration very short, wear of
friction disc will not be severe. So friction discs usu-
ally a have long service life when they are used in a
hydro-viscous soft starter. Compared with the oil film
thickness, the peak value of the surface roughness is
rather small, so only a small error will be incurred in
the calculation if the surface texture is treated as iso-
tropic.
Pressure distribution of the oil film should be cal-
culated in order to calculate load capacity. Pressure
distribution under the condition of an oil film thick-
ness of 0.2 mm and an output speed of 108 r/min is
shown in Fig. 4a. It can be seen that the effect of dy-
rather thick. In fact, the effect of dynamic pressure is
not clear during the entire startup process, because
near the end of the startup process the oil film is thin
but the rotational speed difference becomes very
small. In order to observe the dynamic pressure effect
more clearly, let the inlet pressure be equal to 0 MPa.
The results are shown in Fig. 4b. Fig. 4c shows the
dynamic pressure affected by temperature. It can be
seen that the dynamic pressure is clearly reduced near
the outlet of the friction disc, because of rising tem-
perature. The temperature distribution is shown in Fig.
4d. It can be seen that the variation in temperature is
great along the radial direction but rather small in the
circumferential direction.
Fig. 5a shows the torque transferred by the oil film
during the startup process. It can be seen that the
grooves have a great effect on torque transfer, but the
effect of temperature is rather small. It indicates that

Fig. 4 Distribution of pressure and temperature

(a) Variation of torque transfer of oil film during startup process (b) Variation of load capacity of oil film during startup process
Fig. 5 Torque transfer and load capacity of oil film during startup process
464 Journal of China University of Mining & Technology Vol.18 No.3

the effect of temperature can be neglected in design-
ing a hydro-viscous clutch which can be compensated
by feedback in the control system. Fig. 5b shows the
load capacity of the oil film. It can be seen the load
capacity varies slightly during the startup process.
This agrees with the preceding theoretical analysis.
Since the pressure of the feed cylinder should vary
with the load capacity of the oil film, it is obviously
not the best choice to take pressure as a control object
in the design of a control system. According to the
theory of fluid power transmission and control tech-
nology, it is better to take flow rate as the control ob-
ject.
7 Experimental verification
A belt conveyor is usually considered to be a con-
stant torque device during the startup process. In this
experiment a disc brake was adopted to simulate a
belt conveyor. Torque generated by the disc brake
works as a load, it is acquired by a torque sensor and
pressure of the feed cylinder is acquired by the pres-
sure sensor installed in the electro-hydraulic propor-
tional control system.
Fig. 6a shows our experimental equipment. There
are two sets of electro-hydraulic proportional control
systems, one uses a proportional pressure valve type
DBETE-5X/5G24 of Rexroth. The other is a propor-
tional flow valve type 2FRE6A-2X/2 of Rexroth. A
microcontroller, Atmega16, was used in the electric
control system and the control strategy was fuzzy
PID.
Output speed curves are shown in Fig. 6b. It can be
seen that the speed curve using flow rate as control
object is close to that using pressure as the control
object in the first 20 seconds. But the former flow
rate is better in the last 20 seconds. During the entire
startup process, the speed curve using flow rate as the
control object can approach the theoretical curve
more accurately. But there are deflections to varying
degrees between the experimental and theoretical
curves and improvement of the control system is de-
sired to reduce these deflections.
Fig. 6c shows variation in the pressure of the feed
cylinder during the startup process when flow rate
taken as the control object. It can be seen that it is
coincident with calculation results shown in Fig. 5b.
It proves the validity of our theoretical analysis and
calculations.

(a) Experimental equipment

1. Motor; 2,4,6. Couplings; 3. Hydro-viscous clutch; 5. Torque sensor;
7. Disc brake; 8. Electric control system; 9. Electro-hydraulic proportional control system

(b) Velocity curve (c) Variation of pressure of feed cylinder

Fig. 6 Experimental equipment and results

8 Conclusions not be severe. Friction discs usually have a long ser-

vice life.
A hydro-viscous clutch works at a hydrodynamic Friction disc surface grooves are the basis of
lubrication stage during most of the time of the forming dynamic pressure, but they may reduce the
startup process, so that wear of the friction discs will capacity of torque transfer at the same time. The ef-
MENG Qing-rui et al Mechanism of hydro-viscous soft start of belt conveyor
fect of dynamic pressure is not so clear during the
entire startup process and the effect of the inlet pres-
sure is significant.
Temperature has little effect on a hydro-viscous
soft start, indicating that the effect of temperature can
be neglected in designing a hydro-viscous clutch.
This may be compensated for by feedback in the con-
trol system.
The load capacity varies slightly during the startup
process, indicating it is not the preferred choice to
take pressure as the control object to design a control
system. It is better to take flow rate as the control
object.
Acknowledgement
The authors gratefully acknowledge the reviewer(s)
for his/their constructive comments.
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