Minerals Engineering 84 (2015) 15–26

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Minerals Engineering
journal homepage: www.elsevier.com/locate/mineng

Innovative structural solution for heavy loaded vibrating screens

Sergio Baragetti ⇑
GITT – Centre on Innovation Management and Technology Transfer, Università degli Studi di Bergamo, via Salvecchio 19, 24129 Bergamo, Italy
Department of Management, Information and Production Engineering, Università degli Studi di Bergamo, Viale Marconi 5, 24044 Dalmine, BG, Italy

a r t i c l e i n f o a b s t r a c t

Article history: An innovative design solution is presented in this paper; it allows the enhancement of structural
Received 2 July 2015 resistance and the dynamic performances of a vibrating screen for inert materials. The new design does
Revised 15 September 2015 not significantly affect the geometry of the traditional screens, keeping the same global dimensions and
Accepted 16 September 2015
almost the same mass value. In fact the aim of this study was to design a new vibrating screen having
almost the same dimensions but that could give a much higher dynamic structural resistance at
frequencies and load amplitudes much higher than the nominal ones. Numerical finite element models
Keywords:
were generated to investigate the structural and dynamic behavior of a standard vibrating screen.
Vibrating screens
New structure
These analyses allowed the modification of the geometrical parameters of the traditional screen and to
Higher acceleration design the new one. Accurate three-dimensional FE models were so generated in order to evaluate the
Resistance best design solution, in terms of dynamic structural resistance, able to reduce the stress values at the
Dynamic optimization most stressed area. The fatigue resistance of all the components of the new screen was checked, with
particular attention to the welding joints. Experimental full scale tests on a prototype of the new screen
were carried out in order to validate the numerical models and mostly to verify the structural integrity of
the vibrating screen during the working conditions. Strains at the surface of the most stressed areas of the
screen were measured in dynamic working conditions, at different frequencies and load amplitudes;
these stress values were compared with the numerical ones in order to validate the numerical results.
The new screen was patented.
Ó 2015 Elsevier Ltd. All rights reserved.

1. Introduction
Heavy loaded vibrating screens, horizontal or inclined, are
mounted at the top of batch type asphalt plants or continuous
asphalt plants. The screen allows the selection and segregation of
prescribed components of an aggregation of pebbles and stones
according to specific particle size. The accuracy of the selection is
very important in a lot of applications for which reaching the cor-
rect recipe of the final mixture is mandatory. Among such applica-
tions the asphalt plants, that allow the production and installation
of the asphalt for roads and highways, require a perfect dosage of
all the components. A prescribed percentage of inert materials
with designed particle size has to be achieved for the asphalt mix-
ture and a good vibrating screen has to guarantee its performances
for 24 h a day (Smith et al., 2001; Bringiotti, 2001).
The temperature of the inert materials that flow through the
vibrating screen is in the range 150–200 °C. Pebbles and stones have
to be accurately heated and dehydrated before the classification by
⇑ Address: Department of Management, Information and Production Engineering,
Università degli Studi di Bergamo, Viale Marconi 5, 24044 Dalmine, BG, Italy
E-mail address: sergio.baragetti@unibg.it
screen in order to be ready to be put in the mixture and bond to the
other constituents of the asphalt. The asphalt production plant is
usually a vertical tower which can be up to 30 m high. The inert
materials (pebbles and stones) have to be pre-dosed, heated and
dehydrated before entering the vibrating screen at the top of the
tower (they reach the top of the tower by means of a bucket elevator
that feeds a drying heater). After the screening process the pebbles
of different particle sizes are gathered into steel hoppers put under
the screen. The material stored in the hoppers feeds the mixer
according to prescribed percentage ratios; during the mixing
process the bitumen is added with specified additives that allow
the production of a compact texture asphalt.
Dynamic analysis of the screen has was done in order to proceed
with the design of the new modified screen presented in this paper.
The literature survey of the papers dealing with the study of the
dynamic behavior of the screen was carried out. In (He and Liu,
2009) the authors proposed a theoretical model for the dynamic
behavior evaluation of vibrating screens and a new screen with
elliptical trace was presented. The multi degree of freedom
vibration theory was used and no experimental validation of the
model was presented. In (Zhao et al., 2009) the aim of the paper
is to improve the reliability of large vibrating screens. The authors

http://dx.doi.org/10.1016/j.mineng.2015.09.011
0892-6875/Ó 2015 Elsevier Ltd. All rights reserved.
16 S. Baragetti / Minerals Engineering 84 (2015) 15–26
Nomenclature
A horizontal distance between the center of gravity and
the unload side spring support (m)
A0 vertical distance between the center of gravity and the
unload side spring support – positive in the downward
direction (m)
B horizontal distance between the center of gravity and
the load side spring (m)
B0 vertical distance between the center of gravity and the
load side spring – positive in the upward direction (m)
C = 2R/d spring curvature ratio
c1 total longitudinal damping coefficient of the springs
related to the unload side supports (Ns/m)
ct1 total transverse damping coefficient of the springs
related to the unload side supports (Ns/m)
c2 total longitudinal damping coefficient of the springs
related to the load side supports (Ns/m)
ct2 total transverse damping coefficient of the springs
related to the load side supports (Ns/m)
c total longitudinal damping coefficient of the supports
(Ns/m)
ct total transverse damping coefficient of the supports
(Ns/m)
cc critical damping coefficient in the longitudinal direction
(Ns/m)
cct critical damping coefficient in the transverse direction
(Ns/m)
d wire diameter of the spring (m)
e eccentricity of the direction of application of the active
force with respect to the center of gravity (m)
E longitudinal elastic modulus of the spring (MPa)
F0 active force amplitude (N)
F0,x horizontal component of the active force (N)
F0,y vertical component of the active force (N)
F FEM model active force amplitude (N)
present a new design of a hyperstatic net-beam structure and an
optimal dynamic analysis of the vibrating screen. Finite element
models of the screen were developed and the new screen proves
to have much higher structural strength with an enhanced dynamic
behavior. More recently the author of this paper proposed a general
theoretical model to study the dynamic behavior of high loaded
vibrating screens (Baragetti and Villa, 2014). A general dynamic
theoretical model is proposed and a procedure for dynamic opti-
mization of the main parameters of a screen is described. Dynamic
and static finite element models of a high loaded screen were devel-
oped and the theoretical procedure was implemented in MatlabÒ.
Tests were carried out on a full scale screen in order to confirm
the theoretical and numerical models. A complete experimental
strain gages campaign was prepared and several dynamic tests
were carried out confirming the values of the dynamic stresses cal-
culated through the FEM models. The model presented in Baragetti
and Villa (2014) is the most complete and recent one. For this rea-
son it is used in this paper to quantify the dynamic behavior of the
original and of the new modified screen. The particle flow might
have influence on the dynamic behavior and resistance of the
screen too. DEM (Discrete Element Method) was used to simulate
the particle flow in vibrating screens in Dong et al. (2009), Cleary
et al. (2009a,b), Zhao et al. (2011), Wang and Tong (2011), Li et al.
(2003). In Dong et al., 2009 the authors consider a banana screens
of large dimensions (three decks or five decks). Numerical
experiments (3D DEM models) were used to set and control the per-
formances of the screens, useful to optimize and control the screen-
ing process. Screens performances were improved by reducing the
operating amplitude and frequency of vibrations. In (Cleary et al.,
Fx FEM model horizontal component of the active force (N)
Fy FEM model vertical component of the active force (N)
G transversal elastic modulus of the spring (MPa)
k single spring longitudinal stiffness (N/m)
kt single spring transversal stiffness (N/m)
k1 total longitudinal stiffness of the springs related to the
unload side supports (N/m)
kt1 total transverse stiffness of the springs related to the
unload side supports (N/m)
k2 total longitudinal stiffness of the springs related to the
load side supports (N/m)
kt2 total transverse stiffness of the springs related to the
load side supports (N/m)
K total longitudinal stiffness of the supports (N/m)
Kt total transverse stiffness of the supports (N/m)
m global mass of the system (kg)
n electric engines rotational speed (rpm)
R radius of the spring helix (m)
a inclination of the active force with respect to the verti-
cal (°)
dST static displacement (mm)
h pitching angle of the vibrating screen (°)
Jg global moment of inertia of the system (kg m2)
y vertical coordinate of the center of gravity (m)
x horizontal coordinate of the center of gravity (m)
x electric engines pulsation (rad/s)
xD frequency of the damped system (rad/s)
xF pffiffiffiffiffiffiffiffiffiffiffiffiffiffi
angular frequency of the loading force (rad/s)
xN ¼ K eq =M natural frequency of the system (rad/s)
xnx angular frequency of the system in the transversal
direction (rad/s)
xny angular frequency of the system in the longitudinal
direction (rad/s)
2009a,b) a large double deck banana screen for high accelerations
was studied and the DEM method was implemented to study and
improve the performances. Different peak accelerations were sim-
ulated. In (Zhao et al., 2011) and (Wang and Tong, 2011) the
Authors simulate the screening process on a circularly vibrating
screen using 3D-DEM and evaluated the screening efficiency and
screen length of a linear vibrating screen. In (Li et al., 2003) the
DEM numerical method was used to simulate particle motion. Par-
ticle kinetics and motion were treated in other references (Liu,
1999; Beunder and Rem, 1999; Soldinger, 1999; Soldinger, 2002;
Soldinger, 2000). In (Liu, 1999) the author gave guidelines to check
the screening performance and efficiency and checked the effects of
many process parameters. In (Beunder and Rem, 1999) the authors
report an accurate study of the screening dynamic motion of cylin-
drical particles. Full scale tests were conducted by using a CCD-
camera and an image analyzing software. The measurements give
a good prediction of the grade of separation and the particle distri-
bution is like the one of a closed surface. In (Soldinger, 1999;
Soldinger, 2002; Soldinger, 2000) the author reports studies on
the transport velocity of the material on the screen, the analysis
of the mechanisms of stratification and passage of the material
through the screen and the study of the effect of particle size on
the screening performance. After the accurate analysis of the liter-
ature papers dealing with the study of the particle flow in the
screen, it was decided not to consider the effects of the particle flow
in the design of the new modified screen. Particle flow depends of
the screen process acceleration and amplitude of vibration and does
not have any effect of the dynamic behavior of the machine or its
structural resistance. Therefore it was decided not to consider this
 S. Baragetti / Minerals Engineering 84 (2015) 15–26
parameter. In fact it is important to design high acceleration vibrat-
ing screens and vary the acceleration according to the required per-
formance. The study of the structural resistance of the screen is
reported in few literature references notwithstanding the subject
is extremely important. The structural resistance of the screen is
in fact considered in this paper. In (Steyn, 1995) the fatigue failure
analysis of the support beam of a vibrating screen is reported.
A double deck screen was considered and the fatigue assessment
was done according to BS 5400 standard. (Steyn, 1995) is one of
the few references, as far as the author of this paper knows, in
which the structural assessment of a vibrating screen failure was
studied. The failure occurred at the beam area of the screen, were
the vibrating motors are installed. The operating frequency of the
screen was 15 Hz and millions of cycles can be reached in some
hundreds of hours. The screen is expected to work for 30,000 h,
and special attention has to be paid to the stress–strain and fatigue
design of all the structural components of the screen. The screen
studied in Steyn (1995) was a large screen of dimensions 6.5 m
by 3.0 m. The screen is comparable to the one presented in this
paper and the fatigue resistance analysis proved to be useful even
for the new modified screen.
The aim of this work is to propose a new design solution for
vibrating screens that does not significantly modify the geometry
of the traditional screens, keeping the same global dimensions
and almost the same mass value and at the same time exhibit a
much higher dynamic structural resistance at frequencies, acceler-
ations and load amplitudes much higher than the nominal ones.
Accurate three-dimensional FE models were generated in order
to evaluate the best design solution, in terms of dynamic structural
resistance, able to reduce the stress values at the most stressed
areas. Fatigue resistance of the components of the new screen
was checked with particular attention to the welded joints.
Experimental full scale tests on a prototype of the new screen were
carried out in order to validate the numerical models and mostly to
verify the structural integrity of the vibrating screen during work-
ing conditions. Strains at the surface of the most stressed areas of
the screen were measured in dynamic working conditions, at dif-
ferent frequencies and load amplitudes; these strain values were
compared with the numerical ones in order to validate the numer-
ical results. The new design of the vibrating screen was patented
(Baragetti et al., 2006/2007). Vibrating screens are usually made
of low carbon steel and the components of the screen can be
assembled both by means of bolted connections or by using
welded joints. Bolted and welded connections are currently used
to build structures that can rarely be used under dynamic loads
where a large vibrating load is expected to act on the equipment.
For this reason bot the reliability and the performances of vibrating
screens have to accurately verified. The utilization of higher quality
materials and the implementation of non-destructive control
processes of higher quality welded connections would put the
vibrating screen out of the market. On the other hand the asphalt
producers require always better performances (quantity of
screened material per hour) and absolute absence of fatigue
induced damages during the 24 h per day screening process.
Bearing in mind these consideration it was decided not to change
the materials or the welding technological process to connect the
components of a screen but to modify the structure of the vibrating
screen in order to improve its performances.
2. The vibrating screen
A sample plant for the production of the road asphalt is shown
in Fig. 1.
The vibrating screen studied in this paper is a low carbon steel
made one. The body is made of S255 while the beam that bears the
electric vibrators is made of S275 according to the International
17
Standard EN 10025. A picture of the screen and its main measure-
ment parameters are shown in Fig. 2.
The vibrating screen of the type shown in Fig. 2 is composed of
screening surfaces that are supported by the side-walls of the
screen. The screen has four supports with springs that regulate
the force transmission to the base during the screening process.
Vibrating motors, giving a suitable dynamic load with specified fre-
quency and acceleration, are installed on the beam of the screen.
Vibrations with defined frequency and acceleration allow the
transport of material on different screening surfaces made of wire
mesh (or perforated screen) so the largest fragments remain on the
top mesh and the finest on the bottom mesh. The vibration motor
is an electromechanical motor with eccentric masses. The dynam-
ics loads exerted by the vibrating motors can cause fatigue damage
at the beam area, at the side-walls and at the supports on the
springs. The structures have to be designed to be as strong as
required but not too heavy. The accelerations usually reached are
in the range of 4–5 g. However, higher accelerations would be of
interest because the greater the acceleration, the higher perfor-
mances of the screen. In his paper the new model of the vibrating
screen allows to reach accelerations in the range of 18–20 g, four
times higher than the normally used accelerations. The new
structures proved to have good dynamic performances, almost
the same mass as the unmodified original screen and reduced
manufacturing costs. The principal dimensions and characteristics
of the screen are reported in Table 1.
3. Theoretical model of the dynamic behavior of the screen
The dynamic behavior of the vibrating screens was accurately
studied in Baragetti and Villa (2014). It is assumed that tempera-
ture and the inert material flowing through the vibrating screen
have no effects on the dynamic behavior of the mechanical system.
The screen was schematized as a rigid body having the dimensions
of the real screen and the same mass and inertia properties. This
hypothesis is supported by the fact that the stiffness of the springs
on which the screen is mounted is much lower than the stiffness of
the steel structure of the screen itself. The equilibrium equations
were written first and the analysis of the harmonic behavior of
the screen was performed; the natural frequencies of the vibrating
screens were calculated afterward and the model gave the kinetic
and dynamic parameters needed to calculate all the forces acting
on the structure (displacement, velocity and acceleration fields).
The whole screen has six degrees of freedom, three rotational
and three translational degrees of freedom but the three dimen-
sional problem can be easily studied as a planar problem, reducing
the number of degrees of freedom to three, two translational and
one rotational degree of freedom as shown in Fig. 2b. For a better
selection of the material that flows through the screen the angle
h (Fig. 2b), the pitching angle, should be kept constant and equal
to zero. In fact, the pitching angle varies significantly only during
the start-up phase of the screening process but these variations
tend to reduce to zero as soon as the vibrating screen reaches
the normal working condition (the start-up phase usually takes
no longer than some tens of seconds). The inertial forces along
the coordinate axis are assumed to be concentrated in the center
of gravity of the structure. The weight of the whole structure will
not be taken into account in the dynamic equilibrium equations
because it only has an influence on the static equilibrium position
of the screen. The model takes account of the axial behaviour of the
springs that support the screen as well as their shear and hysteretic
damping behavior.
The analytic scheme of the vertical and horizontal dynamic of
the screen is shown in Fig. 3.
18 S. Baragetti / Minerals Engineering 84 (2015) 15–26

Beam
Side-walls
Elevator
Vibrang motor
Unloading side

Aggregate
weighing Aggregate
storage bins
Asphalt
weighing Loading side
Mixer
Screening
surfaces
Supports

(a) (b)

Fig. 1. (a) Example of a batch type asphalt plant: the vibrating screen is at the top of the plant and (b) main components of the heavy loaded vibrating screen.

Beam supporting the

Vibrang motors

Vibrating motor
Side wall

Supporting
springs A’

Test equipment
(a) (b)

Fig. 2. (a) Picture of the vibrating screen and (b) sketch of the vibrating screen.

The amplitude of the force given by the electric vibrators It is possible to simplify system (3) by introducing the following
mounted at the top of the screen is: terms (4):
K Aeq ¼ k1 þ k2 — K Teq ¼ kt1 þ kt2 — C ¼ c1 þ c2 — D ¼ A0 c1  B0 c2
F 0 ðtÞ ¼ me x2 cosðxtÞ ð1Þ
E ¼ kt1 A0  kt2 B0 — G ¼ ct1 þ ct2 — H ¼ Act1  Bct2 — I ¼ k2 B0  k1 A0
The hysteretic damping forces given by the springs are the fol- L ¼ k1 A  k2 B— M ¼ kt1 A0  kt2 B0 — N ¼ c1 A  c2 B— O ¼ ct1 A0  ct2 B0
lowing ones (2): P ¼ kt1 A02 þ kt2 B02 þ k1 A2 þ k2 B2 — Q ¼ c1 A2 þ c2 B2 þ ct2 B02 þ ct2 A02
8 _ 1 F X ¼ F 0x cosðxtÞ— F Y ¼ F 0y cosðxtÞ— F ¼ F 0 cosðxtÞ
>
> F c1 ¼ ðx_ þ AhÞc
>
< ð4Þ
_ 2
F c2 ¼ ðx_  BhÞc
ð2Þ
> _ t1
> F tc1 ¼ ðy_ þ AhÞc By using the terms listed in (4), the system of equilibrium dif-
>
:
_ ferential Eq. (3) changes into system (5):
F tc2 ¼ ðy_  BhÞct2
8
_
The differential dynamic equilibrium equations of the < m€x þ C x_ þ K Teq x þ Dh þ Eh ¼ F X
>
mechanical system are reported in the system of Eq. (3): my € þ Gy_ þ Hh_ þ K Aeq y þ Ih ¼ F Y ð5Þ
>
:
J h þ Q h_ þ Ox_ þ Ny_ þ Mx þ Ly þ Ph ¼ eF
€

8
>
> m€x þ c1 x_ þ c2 x_ þ A0 c1 h_  B0 c2 h_ þ kt1 x þ kt2 x þ kt1 A0 h  kt2 B0 h ¼ F 0x cosðxtÞ
>
>
< my€ þ ct1 y_ þ ct2 y_ þ Act1 h_  Bct2 h_ þ k1 y þ k2 y þ k2 B0 h  k1 A0 h ¼ F 0y cosðxtÞ
ð3Þ
>
> k1 Ay þ kt1 A h þ c1 Ay_ þ c1 A h_ þ ct1 A x_  c2 By_ þ c2 B2 h_ þ ct2 B02 h_  ct2 B0 x_ þ kt2 B02 h  k2 By þ ct2 A h_ þ k1 A h þ k2 B2 h
02 2 0 02 2
>
>
: 0 0 €
þkt1 A x  kt2 B x þ J h ¼ e  F 0 cosðxtÞ
 S. Baragetti / Minerals Engineering 84 (2015) 15–26 19

The vibrating screen gives the best performances, in terms of Equations in (8) are two second order ordinary differential
selected inert material, if the conditions reported in (6) are equations that give the following solution for the dynamic behav-
satisfied: ior along the x and y directions respectively (Eq. (9)) (Rao, 2011;
Blevins, 1979; Dimarogonas, 1996):

8 cx
>
> xðtÞ ¼ eccx xnx t ðC 1 sin xDx t þ C 2 cos xDx tÞ þ KFTeq
0x qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 x 2 2 c x 2  cosðxF t þ ux Þ
1
>
>
>
> 1 ðxnx Þ þð2ccxx xnxF Þ
F
<
yðtÞ ¼ e
cy
ccy xny t F 0y
ðC 3 sin xDy t þ C 4 cos xDy tÞ þ K Aeq sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
1
 cosðxF t þ uy Þ ð9Þ
>
>   2 2  2
>
>
>
> x c x
: F y F
1 xny þ 2ccy xny

8
<h ¼ 0
> The values of the phase displacements are reported in (10) and
h_ ¼ 0 ð6Þ (11):
>
:€ !
h¼0 2nx bx
ux ¼ arctan ð10Þ
1  b2x
The equations governing the screening dynamic behavior are
reported in (7). !
2ny by
8 uy ¼ arctan ð11Þ
< m€x þ C x_ þ K Teq x ¼ F X
> 1  b2y
my€ þ Gy_ þ K Aeq y ¼ F Y ð7Þ
> The first term of the first equation in linear system (9) repre-
: _
Ox þ Ny_ þ Mx þ Ly ¼ eF sents the transient response (the constants C1 and C2 depend on
initial conditions). On the other hand this response tends to fade
In Eq. (7) the optimum parameters for the screening perfor- with time, while the second term of the first differential equation
mance are considered: thus h_ ¼ 0 and the load eccentricity e = 0. in (9) represents the steady-state response, which has the pulsa-
The problem has only two degrees of freedom, one in the x direc- tion out of the phase ux. The same considerations also apply to
tion and one in the y direction. Eq. (7) describes only the stationary the second differential equation in linear system (9). The damping
regime behavior of the screen. With these hypotheses linear sys- ratio is reported in Eq. (12).
tem (7) reduces into linear system (8). c
n¼ ð12Þ
 cc
mx€ þ C x_ þ K Teq x ¼ F X
ð8Þ The frequency ratio is reported in Eq. (13) while the static
my€ þ Gy_ þ K Aeq y ¼ F Y
displacement in Eq. (14).

Table 1
Principal dimensions and characteristics of the screen.

Maximum vertical dimension of the screen 1400

Maximum horizontal dimension of the screen 3000 mm
Number of sections of the screen 6
Mass of the unmodified original screen 1962 kg
Horizontal distance between the springs (loading side-unloading side, A + B in Fig. 2) 2100 mm
Number of springs at the loading side 6
Number of springs at the unloading side 4
Diameter of one spring 127 mm
Diameter of the wire of the springs 17 mm
Number of active coils of the springs 8
Length of one spring 248 mm
Pitch of the springs 29 mm
Axial stiffness of each spring 79,909 N/m
Shear stiffness of each spring 201,979 N/m
Horizontal distance of the center of gravity of the screen from the loading side springs (B in Fig. 2b) 1240 mm
Horizontal distance of the center of gravity of the screen from the discharge side springs (A in Fig. 2b) 860 mm
Vertical distance of the center of gravity of the screen from the loading side springs (B0 in Fig. 2b) 47 mm
Vertical distance of the center of gravity of the screen from the discharge side springs (A0 in Fig. 2b) 247 mm
Type of electrical vibrators ItalvibrasÒ MSVI S90
Number of electrical vibrators mounted on the beam 2
Inclination angle of the beam of the screen on which the vibrators are mounted (a in Fig. 2b) 27°
Frequency of load application of the electrical vibrators 1000 rpm–104.7 rad/s
Maximum load of each vibrator (F0 in Fig. 2b) 100,000 N
Mass of each electric vibrator 381 kg
Static moment of each vibrator 8673 kg mm
Power of each vibrator 7.6 kW
Eccentricity of the applied vibrating load (e in Fig. 2b) for the optimum screening performance 0 mm
20 S. Baragetti / Minerals Engineering 84 (2015) 15–26

Fig. 3. (a) Equivalent dynamic system with two concentrated masses simulating the vibrating motors, (b) dynamic scheme with the equivalent force exerted by the vibrating
motors and (c) vectors of the vibrating screen forces.

2 3
xF m
b¼ ð13Þ
xN 6 7
M¼4 m 5 ð19Þ
F JG
dST ¼ ð14Þ
K eq 2 3
Kt 0 Ht
The damped frequency is reported in Eq. (15). 6 7
K ¼ 40 K H 5 ð20Þ
qffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Ht H ðD þ Dt Þ
xD ¼ xN 1  n2 ð15Þ

The substitution of (12)–(15) into the two equations of linear

Kt  k 0 Ht

m m

system (9) allows to obtain the linear system (16).

1

M K  kI
¼

0 k
¼0
K H

ð21Þ
8
Ht
m m

< xðtÞ ¼ e
> nx xnx t
½C 1 sinðxDx tÞ þ C 2 cosðxDx tÞ þ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
dSTX
2
ffi  cosðxF t þ ux Þ
J H ðDþDt Þ
 k

ð1b2 Þ þð2n b Þ2
x x x GJ G JG

>
: yðtÞ ¼ eny xny t ½C 3 sinðxDy tÞ þ C 4 cosðxDy tÞ þ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
dSTY
 cosðxF t þ uy Þ
2 2
ð1by Þ þð2ny by Þ2 
D þ Dt H2
ð16Þ ðK t =m  kÞðK=m  kÞ  k  ðK t =m  kÞ
JG mJG
The first natural frequencies for the damped system (Rao, 2011; H2t
Blevins, 1979; Dimarogonas, 1996; Hartog, 1984; Childs, 2004; de  ðK=m  kÞ ¼0 ð22Þ
mJG
Silva, 2006), are reported in Eqs. (17) and (18).
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi rffiffiffiffiffi Eq. (22) gives three values of the eigenvalues k. The eigenvalues
 2
Kt Ct Kt and the natural frequencies are linked by the formula x2 ¼ k that
xnx ¼  ffi ð17Þ
m 2m m allows extraction of the three natural frequencies.

sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi rffiffiffiffiffi
 2 4. Results for the original unmodified screen
K C K
xny ¼  ffi ð18Þ
m 2m m
The load and working characteristics of the original unmodified
To obtain the generic natural frequencies of the dynamic screen are reported in Table 1. The vibrating motors are considered
system, the eigenvalues problem has to be solved through to be not exerting their maximum load: the load exerted by the
Eqs. (19)–(22). vibrating devices for the unmodified screen is equal to 130,720 N
with an inclination angle equal to 27° and frequency 104.7 rad/s–
Table 2
Parameters and theoretical results for the horizontal and vertical dynamic behavior of
1000 rpm (Fig. 2b). Table 2 reports the parameters and theoretical
the unmodified screen. results for the horizontal and vertical dynamic behavior of the
screen obtained applying the equations of the theoretical proce-
Eccentricity of the applied vibrating load (e in Fig. 2b) 0 mm
dure reported in Section 3.
for the optimum screening performance
Total longitudinal damping coefficient of the supports c = 1929 Ns/m The first three natural frequencies of the screen, calculated
Total transverse damping coefficient of the supports ct = 763 Ns/m according to Eqs. (19)–(22), are reported in (23).
Static displacement of the switched off screen 24 mm
Natural frequency of the screen in the x longitudinal xx = 32.1 rad/s  x1 ffi 19:8 rad=s ! f 1 ¼ 3:2 Hz
direction
 x2 ffi 31:4 rad=s ! f 2 ¼ 5:1 Hz ð23Þ
Natural frequency of the screen in the y vertical xy = 20.2 rad/s
direction  x3 ffi 47:6 rad=s ! f 1 ¼ 7:6 Hz
Dynamic displacement in the x longitudinal direction 3.2 mm
Dynamic displacement in the y vertical direction 5.9 mm The frequency of load application is 104.7 rad/s–1000 rpm, higher
Frequency ratio in the x longitudinal direction bx = 3.26 than the values reported in (23): this means that the machine will
Frequency ratio in the y vertical direction by = 5.19
not experience any resonance problem during its operations.
Damping ratio in the x longitudinal direction nx = 0.0153
Damping ratio in the y vertical direction ny = 0.0096
Maximum speed in the x longitudinal direction 0.334 m/s 4.1. FEM numerical model of the unmodified original screen
Maximum speed in the y vertical direction 0.617 m/s
Maximum acceleration in the x longitudinal direction 3.57 m/s2
The development of the FEM numerical model of the original
Maximum acceleration in the y vertical direction 6.59 m/s2
unmodified screen allowed verification of its structural resistance
 S. Baragetti / Minerals Engineering 84 (2015) 15–26 21

Fig. 4. Planar half model of the original unmodified screen.

Fig. 5. Mesh, applied loads and boundary conditions of the original unmodified screen.

Fig. 6. Map of the von Mises stresses (MPa).

and structural integrity in the dynamic working conditions. The
finite elements used are three nodes shell elements that allow
generation of a 2D model of the metal sheets composing the
screen. Due to the symmetric working condition only one half of
the screen was modelled, as shown in Fig. 4. The mesh, applied
loads and boundary conditions are shown in Fig. 5.
The FEM model has 14,469 nodes and 26,563 elements. An
accurate evaluation of the worst loading condition was carried
out before running the analysis. As a matter of fact the screen
transfers only a small amount of the load exerted by the vibrating
motors on the beam to the supporting springs. Thus the accelera-
tion acting during the screening process has to be taken into
account. For safety reasons the behavior during the start-up and
arrest transition were considered. This is an unfavorable condition
for which the applied load might cause the contact of the coils of
the springs: this was assumed to be the worst working condition
for the strength of the screen. The contour of the von Mises stresses
(MPa) in different areas of the screen is shown in Fig. 6. Fig. 7
shows the map of the von Mises stresses at the most stressed
areas: beam connection area, loading side support, unloading side
support.
The FEM model allows calculation of the natural frequencies of
the screen. The first five natural frequencies are reported in
Table 3.
The von Mises stresses of the screen in the worst conditions are
never higher than 200 MPa at the notches. Such von Mises stresses
might cause fatigue failure at the welded areas. The natural
frequencies are all much higher than the applied load equal to
104.7 rad/s, thus preventing any resonance problem of the plates
composing the screen.
22 S. Baragetti / Minerals Engineering 84 (2015) 15–26

Fig. 7. Map of the von Mises stresses at the most stressed areas: (a) beam connection area, (b) loading side support and (c) unloading side support (MPa).

Table 3
Table 4
FEM natural frequencies of the vibrating unmodified screen.
Parameters and theoretical results for the horizontal and vertical dynamic behavior of
First FEM natural frequency of the x1 = 23.80 Hz = 149.5 rad/s the new modified screen.
unmodified screen
Second FEM natural frequency of the x2 = 38.37 Hz = 241.0 rad/s Eccentricity of the applied vibrating load (e in Fig. 2b) 0 mm
unmodified screen for the optimum screening performance
Total longitudinal damping coefficient of the supports c = 1929 Ns/m
Third FEM natural frequency of the x3 = 46.53 Hz = 292.4 rad/s
unmodified screen Total longitudinal damping coefficient of the supports ct = 763 Ns/m
Fourth FEM natural frequency of the x4 = 63.03 Hz = 396.0 rad/s Static displacement of the switched off screen 25 mm
unmodified screen Natural frequency of the screen in the x longitudinal xx = 31.4 rad/s
Fifth FEM natural frequency of the x5 = 63.26 Hz = 397.5 rad/s direction
unmodified screen Natural frequency of the screen in the y vertical direction xy = 19.7 rad/s
Dynamic displacement in the x longitudinal direction 4.2 mm
Dynamic displacement in the y vertical direction 7.8 mm
Frequency ratio in the x longitudinal direction bx = 3.34
5. Results for the new structure of the modified screen Frequency ratio in the y vertical direction by = 5.30
Damping ratio in the x longitudinal direction nx = 0.0150
Damping ratio in the y vertical direction ny = 0.0094
Starting from the results obtained for the original unmodified Maximum speed in the x longitudinal direction 0.442 m/s
screen (Section 4) a new design of the body of the vibrating screen Maximum speed in the y vertical direction 0.819 m/s
was proposed. The FEM analysis of the structural behavior of the Maximum acceleration in the x longitudinal direction 4.72 m/s2
unmodified original screen allowed highlighting the weakness of Maximum acceleration in the y vertical direction 8.74 m/s2

the side walls of the screen, particularly at the supports where

the springs are mounted. Furthermore the dynamic behavior of
the machine is greatly influenced by the bending stiffness of the
side walls. The idea was that the increment of the side walls bend-
ing stiffness would prove effective not only for the stress relief at
the supports but also for the dynamic behavior. The idea of the
new reinforced side walls came from the experience of the author
in the aeronautic field. The wings of the airplanes are reinforced in
a similar way. This structural architecture allows improvement
both of the resistance and of the stiffness of the wings, without
increasing their mass and the weight. The modified side walls con-
siderably increase the machine acceleration and performance.
The new design gives a much higher stiffness and fatigue
resistance to the two side-walls of the screen (16 in Fig. 8a)
thus increasing the whole machine acceleration, the rate of
selection and production. The new structure was patented
(Baragetti et al., 2006/2007). Three sketches taken from the patent
are shown in Fig. 8.

Fig. 8. (a) Whole structure of the new modified higher performances screen, (b) geometrical configuration of a side-wall and (c) detail of the new design of each side-wall
(numbered with 16) (Baragetti et al., 2006/2007).
 S. Baragetti / Minerals Engineering 84 (2015) 15–26
The new vibration screen is composed of a case-shaped body
with parallel side-walls (16 in Fig. 8a–c) between which perforated
screening surfaces (17 in Fig. 8a) are located. The body is mounted
over a base (13 in Fig. 8a) through coil springs (12 in Fig. 8a) and is
provided with vibrating motors (14 in Fig. 8a) mounted on a sup-
porting beam (15 in Fig. 8a). The higher stiffness and resistance
of the screen is due to the new design of the side-walls as shown
in Fig. 8c. The side-walls are each composed of two lateral vertical
plate sheets (19 and 20 in Fig. 8c), one close to the other and par-
allel in order to form each of the two faces of the wall. An hollow
space (21 in Fig. 8c) is delimited by the plate sheets. The other
components of Fig. 8 are the following ones: (18) steel mesh;
(22) reinforcements at the supports; (23) interconnecting and
reinforcing elements; (24) connections between the inner and
the outer surface of the side walls; (25) side walls supports of
the coil springs.
The outer sheet thickness is 6 mm, while the inner sheet is
3 mm thick. Notwithstanding the higher stiffness and resistance
of the body of the modified screen, its mass is only 2050 kg with
an increment of 0.04% with respect to the original unmodified
screen having the mass equal to 1962 kg (Table 1). With the same
amount of steel and the same weight the new modified screen can
give much higher performances with higher stiffness and resis-
tance, as shown in Table 4.
The load and working characteristics of the new modified
screen are reported in Table 4. The screen has a higher stiffness
and resistance and the vibrating motors can apply the load up to
190,220 N, approximately the maximum load (Table 1). The
inclination angle of the load is the same and equal to 27° with a
frequency 104.7 rad/s–1000 rpm (Fig. 2b). Table 4 reports the
parameters and theoretical results for the horizontal and vertical
dynamic behavior of the modified screen obtained applying the
equations of the theoretical procedure reported in Section 3.
The first three natural frequencies of the screen, calculated
according to Eqs. (19)–(22) are the same as the unmodified original
screen and are reported in (23). Even for the modified screen the
frequency of load application is 104.7 rad/s–1000 rpm, higher than
the values reported in (23): this means that the machine will not
experience any resonance problem during its working conditions.
The performance of the screen in terms of material selection
amount per unit time is strictly dependent on the acceleration of
the screening process. The acceleration in the x longitudinal direc-
tion is 3.57 m/s2 for the original unmodified screen while is
4.72 m/s2 for the new modified screen with a percentage incre-
ment of 32%. The acceleration in the y vertical direction is
6.59 m/s2 for the original unmodified screen while is 8.74 m/s2
for the new modified screen with a percentage increment of 33%.
5.1. FEM numerical models of the new modified screen
The three dimensional model of the new modified screen is
shown in Fig. 9. Due to the symmetric working condition only
one half of the screen was modelled, as shown in Fig. 9. The mesh,
applied loads and boundary conditions are shown in Fig. 10.
The FEM model has 47,544 nodes and 93,038 elements. Even for
the new modified screen an evaluation of the worst loading condi-
tion was carried out before running the analysis. For safety reasons
the behavior during the start-up and stop transitory were consid-
ered, as done for the original unmodified screen. The contour of
the von Mises stresses (MPa) in different areas of the screen is
shown in Fig. 11.
Fig. 12 shows the map of the von Mises stresses at the most
stressed areas: beam connection area, loading side support,
unloading side support.
Comparison of Figs. 6 and 7 with Figs. 11 and 12 gives evidence
of the huge reduction in the stress state for the new screen with
23
respect to the original unmodified one. The maximum von Mises
stress reduced from 200 MPa to 44 MPa while maintaining almost
the same mass of the screen. With such values of von Mises stres-
ses the screen will not have any problem of fatigue damage. Even
the dynamic behavior is better in terms of natural frequencies
due to the higher stiffness of the structure. The first five natural
frequencies are reported in Table 5.
The natural frequencies are all much higher that the applied
load one equal to 104.7 rad/s, thus preventing any resonance prob-
lem of the plates composing the screen. Furthermore the natural
frequencies of the modified structure are much higher than the
ones of the original unmodified screen.
6. Design of the beam of the screen
For the beam of the new modified screen (Fig. 1b) a HE 550 A –
UNI 5397 profile was chosen. The same beam was used for the
original unmodified machine. The literature formula for the natural
frequencies of the beam is reported in (Rao, 2011; Blevins, 1979;
Dimarogonas, 1996; Hartog, 1984; Childs, 2004; de Silva, 2006).
The length of the beam is 1,400 mm, the inertia moment
around its axis is 1120.14  106 mm4, its cross sectional area is
21,190 mm2, the Young’s modulus is 206  106 (kg mm/s2)/mm2
and the density of the steel material is 7.85  106 kg/mm3.
sffiffiffiffiffiffiffi
ðnpÞ2 EI
xn ¼ n ¼ 1; 2; 3; . . . : ð24Þ
l
2 qA
The lower natural frequency of the beam is x1 = 5,931 rad/s
that corresponds to a frequency f1 = 944 Hz that is approximately
1/10 of the load frequency. This assures good working condition
for the beam and the whole machine, without any resonance
problem.
7. Experimental procedures and comparison with the
theoretical and numerical results
Tests on the full scale new modified screen were carried out in
order to validate the theoretical and numerical models and check
the higher performances of the new modified mechanical system.
Strain gages were put at different areas of the screen and the
strains were measured during the operating conditions of the
machine. A HBM Spider 8Ò dynamic acquisition device was used
to measure the strains. The acquisition device allows measurement
of the signal at a 200 Hz sampling rate. The acquisition device con-
tains 8 measuring amplifiers with carrier frequency from 4.8 kHz
for strain gauge transducers, corresponding to as many channels
numbered from 0 to 7. Each channel operates with an A/D
converter, which allows for measurement speed from 1 Hz to
9600 Hz. In the experimental tests the sampling frequency was
set to 400 Hz in order to ensure the acquisition of data able to
faithfully reproduce the real time trend of the strain and stress
state. 120 ± 35% X electric strain gages having gage factor
2.01 ± 1% were used. The map of the strain gages is shown in
Fig. 13. Six strain gages were put on the beam of the screen in order
to check the applied load (Fig. 13a), two on each stiffened side-wall
of the screen at the unloading side (Fig. 13b), two on the spring
supports at the unloading side (Fig. 13c) and torsional fishbone
strain gages on the supporting springs which allowed checking of
the reaction forces at the supports (Fig. 13d).
Strains were measured at the surface of the structural metal
sheets composing the screen and the stress state is planar (one
principal stress is equal to zero). In case of only one strain gage
aligned to one principal stress direction the simple equation
r ¼ E  e was used to calculate the stress once the strain value from
the strain gages is known. In case of two perpendicular strain
24 S. Baragetti / Minerals Engineering 84 (2015) 15–26

Fig. 9. 3D half model of the new modified screen.

Fig. 10. Mesh, applied loads and boundary conditions of the new modified screen.

Fig. 11. Map of the von Mises stresses of the new modified screen (MPa).

Fig. 12. Map of the von Mises stresses at the most stressed areas of the new modified screen: (a) beam connection area, (b) loading side support and (c) unloading side
support [MPa].
 S. Baragetti / Minerals Engineering 84 (2015) 15–26 25

(
Table 5 r1 ¼ 1Et2  ðe1 þ te2 Þ
FEM natural frequencies of the vibrating new modified screen. ð25Þ
r2 ¼ 1Et2  ðe2 þ te1 Þ
First FEM natural frequency of the x1 = 95.80 Hz = 601.9 rad/s
modified screen Once the surface stress state is measured the von Mises stress
Second FEM natural frequency of the x2 = 105.20 Hz = 661.0 rad/s can be calculated and compared with the numerical FEM values
modified screen
Third FEM natural frequency of the x3 = 113.80 Hz = 715.4 rad/s (Eq. (26)).
modified screen qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Fourth FEM natural frequency of the x4 = 119.50 Hz = 750.8 rad/s rVM ¼ r21 þ r22  r1 r2 ð26Þ
modified screen
Fifth FEM natural frequency of the x5 = 123.40 Hz = 775.3 rad/s For the springs at the supports the value of the shear stresses
modified screen can be calculated by simply multiplying the shear modulus G
and the measured shear deformation c: s ¼ G  c .
The maximum bending stress on the beam of the screen, in
gages, 1 and 2 in Fig. 13a, the stresses can be calculate by using steady state conditions, was measured with strain gage 3 and
equation 25 for a plane stress state. equals 11.3 MPa. The percentage difference between the numerical

2
3
1 4
9

7 8
5
6

10

(a) (b) (c)

(d)
Fig. 13. map of the strain gages (a) on the beam of the screen, (b) on the stiffened flank at the unloading side, (c) at the springs support at the unloading side and (d) on the
springs at the supports.

Fig. 14. Shear deformation values versus time for one of the springs at the loading side during the start-up phase.
26 S. Baragetti / Minerals Engineering 84 (2015) 15–26
Table 6
Comparison between measured and calculated acceleration of the new modified
screen.
rpm Calculated acceleration (g) Measured acceleration (g)
800 4.2 4.0
1000 6.8 6.5
1200 10.1 9.8
1400 12.3 12.1
1500 15.8 15.1
1600 17.1 16.9
FEM value and the experimental one is 7%. Furthermore such value
is much below the fatigue limit of the component. The stresses
measured with strain gages 7 and 8, in steady state conditions,
are equal to 5 MPa with 10% difference if compared to the numer-
ical FEM ones. The maximum stresses measured with strain gages
9 and 10 are equal to 13 MPa in steady state conditions and 25 MPa
during the start-up and stop phases. Even in this area the percent-
age difference with the numerical FEM values is 10% and the stres-
ses are much below the fatigue limit. The shear stress measured by
the torsional strain gages put on the supporting springs is equal to
12 MPa in steady state conditions and 110 MPa during the start-up
and stop phases. The value in steady state condition is comparable
with the theoretical results with a percentage difference less than
10%. A careful evaluation of the start-up and stop phases has to be
carried out: in these phases the stresses at the springs can reach
quite high values and a speed regulator (inverter) might be useful
to reduce the dynamic dangerous conditions that occur in the tran-
sitory regimes. An example of the shear deformation values versus
time are plotted in Fig. 14 for one of the springs at the loading side
during the start-up phase.
An accelerometer was put on the beam of the screen in order to
measure the acceleration of the machine. Table 6 reports the com-
parison between the calculated and measured accelerations. The
percentage differences are negligible thus confirming the accuracy
of the theoretical model and the higher performances of the new
modified screen.
8. Conclusions
A new structural solution for high loaded vibrating screens was
proposed in this paper. The new concept consists of increasing the
structural and functional performance of the screen by means of a
modification of the two side-walls of the mechanical system. The
idea of the design of the new modified side walls came from the
aeronautic field: comparison with the structure of the wings of
the planes allowed designing the new structure. The higher stiff-
ness and resistance of the screen is due to the new design of the
side-walls, each composed of two lateral vertical plate sheets,
one close to the other and parallel in order to form each of the
two faces of the wall. The higher acceleration new structure allows
an increase in the productivity of the mechanical system. The
dynamic and structural behavior of the original and modified
vibrating screens were studied by means of theoretical and numer-
ical models. Full scale experimental tests allowed to confirm the
accuracy of the theoretical and numerical models and proves the
higher performances of the new developed machine.
Acknowledgment
The author wishes to thank Bernardi Impianti for the support of
the research project.
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