A device for replacing an under roller of a belt conveyor

Abstract

The utility model relates to a device of replacing belt conveyor lower carrier roller, including first fixed establishment, first limiting mechanism, first elevating system, first mounting mechanism, second fixed establishment, second limiting mechanism, second elevating system, second mounting mechanism and temporary carrier roller, wherein, first fixed establishment and second fixed establishment symmetrically set up in belt conveyor support both sides, first limiting mechanism, first elevating system, first mounting mechanism and first fixed establishment are used in pairs, second limiting mechanism, second elevating system, second mounting mechanism and second fixed establishment are used in pairs, and temporary carrier roller both ends are placed on first mounting mechanism and second mounting mechanism respectively, form the temporary support of conveying belt empty section. Replacing the fault lower carrier roller with temporary carrier roller supports the conveying belt, so that the belt conveyor can continue to operate in the replacement process, completely avoids the production loss caused by shutdown, and improves production efficiency.

Description

Technical Field

[0001] This utility model relates to the technical field of conveyor belt maintenance equipment, specifically to a device for replacing the lower idler roller of a conveyor belt. Background Technology

[0002] Lower idlers are an important component of belt conveyors, primarily used to support the empty sections of the conveyor belt and ensure stable operation. Specifically, during operation, the lower idlers are evenly distributed beneath the belt, providing continuous support and maintaining the belt at a suitable height and shape. This prevents the belt from sagging or deforming due to its own weight and the weight of the material, which would affect the normal transport of materials. The presence of the lower idlers transforms the contact between the belt and the frame into rolling friction, significantly reducing friction, energy consumption, and extending the service life of both the belt and the frame. High-quality lower idlers have excellent rotational performance, rotating smoothly with the belt's movement, reducing sliding friction between the belt and the idler, resulting in smoother and faster belt operation and improving the conveyor's efficiency.

[0003] Belt conveyors are commonly used material handling equipment in paper mills. During production, issues such as damaged, jammed, or abnormally noisy lower idler roller bearings on belt conveyors require timely attention. Currently, operators typically perform maintenance by stopping the machine. However, this method of stopping the machine to repair the lower idler rollers disrupts normal production and reduces efficiency. Utility Model Content

[0004] Therefore, there is a need for a device for replacing the lower idler roller of a belt conveyor, which solves the technical problem that currently, when maintaining the lower idler roller of a belt conveyor, operators usually have to stop the machine to carry out maintenance work. This method of stopping the machine to maintain the lower idler roller of the belt conveyor affects normal production and reduces production efficiency.

[0005] To achieve the above objectives, the inventor provides a device for replacing the lower idler roller of a belt conveyor, comprising:

[0006] The first fixing mechanism is fixedly installed on one side of the belt conveyor's support frame;

[0007] A first limiting mechanism is disposed below the first fixing mechanism and is fixedly connected to the first fixing mechanism. The first fixing mechanism is used to fix the first limiting mechanism.

[0008] A first lifting mechanism is disposed outside the first fixed mechanism;

[0009] A first installation mechanism, wherein the first limiting mechanism is disposed on the first lifting mechanism and the first installation mechanism passes through the first limiting mechanism, the first lifting mechanism is used to lift the first installation mechanism, and the first limiting mechanism is used to limit the first installation mechanism;

[0010] The second fixing mechanism is fixedly installed on the other side of the belt conveyor's support frame, and the second fixing mechanism is arranged opposite to the first fixing mechanism;

[0011] The second limiting mechanism is disposed below the second fixing mechanism. The second limiting mechanism is fixedly connected to the second fixing mechanism. The second limiting mechanism is disposed opposite to the first limiting mechanism. The second fixing mechanism is used to fix the second limiting mechanism.

[0012] The second lifting mechanism is located outside the second fixing mechanism;

[0013] The second installation mechanism is provided on the second lifting mechanism, and the second installation mechanism passes through the second limiting mechanism. The second lifting mechanism is used to lift the second installation mechanism, and the second limiting mechanism is used to limit the second installation mechanism.

[0014] And a temporary idler roller, one end of which is placed on the first mounting mechanism and the other end of which is placed on the second mounting mechanism. The first mounting mechanism and the second mounting mechanism cooperate with each other to place the temporary idler roller.

[0015] As a preferred structure of this utility model, both the first fixing mechanism and the second fixing mechanism include a fixing slot, an upper fixing component and a lower fixing component;

[0016] The upper fixing component is disposed at the top of the fixing slot, and the lower fixing component is disposed at the bottom of the fixing slot;

[0017] The first limiting mechanism is fixedly connected to the fixed slot, and the second limiting mechanism is fixedly connected to the fixed slot;

[0018] The upper fixing component and the lower fixing component cooperate with each other to fix the fixing slot to the bracket of the belt conveyor.

[0019] As a preferred structure of this utility model, the top of the fixing slot is provided with an upper fixing hole, and the bottom of the fixing slot is provided with a lower fixing hole;

[0020] The upper fixing component passes through the upper fixing hole and is connected to the fixing slot by a thread;

[0021] The lower fixing component passes through the lower fixing hole and is connected to the fixing slot by a thread.

[0022] As a preferred structure of this utility model, the upper fixing hole is disposed on the outer side of the top of the fixing slot, and the lower fixing hole is disposed on the inner side of the bottom of the fixing slot.

[0023] As a preferred structure of this utility model, there are two upper fixing holes, which are arranged opposite to each other at a distance; there are two upper fixing components, which are arranged opposite to each other at a distance.

[0024] There are two lower fixing holes, which are arranged opposite each other at a distance. There are two lower fixing components, which are arranged opposite each other at a distance.

[0025] As a preferred structure of this utility model, both the first limiting mechanism and the second limiting mechanism include a first limiting plate and a second limiting plate;

[0026] The top of the first limiting plate is fixedly connected to the bottom of the fixing slot, and the top of the second limiting plate is fixedly connected to the bottom of the fixing slot.

[0027] The first limiting plate and the second limiting plate are arranged opposite each other at a distance, and a gap is left between the first limiting plate and the second limiting plate.

[0028] As a preferred structure of this utility model, both the first lifting mechanism and the second lifting mechanism include a fixed cylinder, a screw, and a fixed nut.

[0029] The fixing cylinder is fixedly disposed on the outside of the fixing slot;

[0030] One end of the screw passes through the fixed cylinder from top to bottom, the first mounting mechanism is disposed at the other end of the screw, and the second mounting mechanism is disposed at the other end of the screw;

[0031] The fixing nut is disposed on the other end of the screw, and the fixing nut is connected to the screw by a thread. The fixing nut is located below the first mounting mechanism and the fixing nut is disposed below the second mounting mechanism.

[0032] As a preferred structure of this utility model, both the first lifting mechanism and the second lifting mechanism are hydraulic cylinders, pneumatic cylinders, or electric cylinders.

[0033] As a preferred structure of this utility model, both the first mounting mechanism and the second mounting mechanism include a mounting base, and the mounting base passes through the gap between the first limiting plate and the second limiting plate and is connected to the first lifting mechanism;

[0034] The mounting base passes through the gap between the first limiting plate and the second limiting plate and connects to the second lifting mechanism.

[0035] As a preferred structure of this utility model, both the first mounting mechanism and the second mounting mechanism further include a mounting groove, which is disposed on the mounting base.

[0036] The advantages of the above technical solution, which differ from existing technologies, are as follows:

[0037] Achieve non-stop replacement: By replacing the faulty idler with a temporary idler to support the conveyor belt, the belt conveyor can continue to operate during the replacement process, completely avoiding production losses caused by downtime and improving production efficiency (taking a paper mill as an example, each replacement can save more than 1 hour of downtime, saving more than 100,000 yuan in annual production capacity loss).

[0038] Easy and efficient operation: The device adopts a modular design, with installation and disassembly time ≤10 minutes and total replacement time of a single lower idler roller ≤15 minutes, which improves efficiency by 2-4 times compared to traditional downtime maintenance; ordinary operators can operate it proficiently after 1 hour of training, without the need for professional maintenance personnel.

[0039] High adaptability: With adjustable first and second fixing mechanisms and replaceable temporary idlers, it covers more than 90% of belt conveyor specifications in paper mills, with high adaptability and no need for customized special equipment.

[0040] The above description of the utility model is merely an overview of the technical solution of this application. In order to enable those skilled in the art to better understand the technical solution of this application and to implement it based on the description and drawings, and to make the above-mentioned objectives and other objectives, features and advantages of this application easier to understand, the following description is provided in conjunction with the specific embodiments and drawings of this application. Attached Figure Description

[0041] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of specific embodiments of this application and other related content, and should not be considered as limitations on this application.

[0042] In the accompanying drawings of the instruction manual:

[0043] Figure 1 This is a side view of the device for replacing the lower idler roller of the belt conveyor as described in the specific embodiment;

[0044] Figure 2 This is a front view of one side of the device for replacing the lower idler roller of the belt conveyor as described in the specific embodiment.

[0045] Figure 3 This is a rear view of one side of the device for replacing the lower idler roller of the belt conveyor as described in the specific embodiment.

[0046] Figure 4 This is a side view of one side of the device for replacing the lower idler roller of the belt conveyor as described in the specific embodiment;

[0047] Figure 5 This is a front view of the other side of the device for replacing the lower idler roller of the belt conveyor as described in the specific embodiment.

[0048] The reference numerals used in the above figures are explained as follows:

[0049] 1. First fixed mechanism,

[0050] 11. Fixed card slot,

[0051] 12. Install the fixing components.

[0052] 13. Lower fixing component,

[0053] 14. Upper fixing hole,

[0054] 15. Lower fixing hole,

[0055] 2. First limiting mechanism,

[0056] 21. First limiting plate,

[0057] 22. Second limiting plate,

[0058] 3. First lifting mechanism,

[0059] 31. Fixed cylinder

[0060] 32. Screw,

[0061] 33. Secure the nuts.

[0062] 4. First installation mechanism,

[0063] 41. Mounting base,

[0064] 42. Mounting slot,

[0065] 5. Second fixed mechanism,

[0066] 6. Second limit mechanism,

[0067] 7. Second lifting mechanism,

[0068] 8. Second installation mechanism,

[0069] 9. Temporary idler rollers. Detailed Implementation

[0070] To illustrate the possible application scenarios, technical principles, implementable specific solutions, and achievable objectives and effects of this application in detail, the following description, in conjunction with the listed specific embodiments and accompanying drawings, provides a detailed explanation. The embodiments described herein are merely illustrative of the technical solutions of this application and are therefore intended to limit the scope of protection of this application.

[0071] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0072] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit this application.

[0073] In the description of this application, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " in this document generally indicates that the preceding and following objects have an "or" logical relationship.

[0074] In this application, terms such as “first” and “second” are used only to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy or order relationship between these entities or operations.

[0075] Unless otherwise specified, the use of terms such as “comprising,” “including,” “having,” or other similar expressions in this application is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a list of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.

[0076] Similar to the understanding in the Examination Guidelines, in this application, expressions such as "greater than," "less than," and "exceeding" are understood to exclude the stated number; expressions such as "above," "below," and "within" are understood to include the stated number. Furthermore, in the description of the embodiments in this application, "multiple" means two or more (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times," unless otherwise explicitly specified.

[0077] In the description of the embodiments of this application, the space-related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. These expressions are only for the convenience of describing the specific embodiments of this application or for the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application. Furthermore, in this context, it should be understood that when it is mentioned that an element is connected "on" or "below" another element, it can be directly connected not only to the other element "on" or "below," but also indirectly connected to the other element "on" or "below" through an intermediate element.

[0078] Unless otherwise expressly specified or limited, the terms "installation," "connection," "linking," "fixing," and "setting," as used in the description of the embodiments of this application, should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral setting; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. For those skilled in the art to which this application pertains, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0079] Please see Figures 1 to 5 This embodiment relates to a device for replacing the lower idler roller of a belt conveyor, comprising:

[0080] The first fixing mechanism 1 is fixedly installed on one side of the belt conveyor support. The first fixing mechanism 1 is the basic component for connecting the device with the belt conveyor support, and is used to stably fix the left side of the device to one side of the belt conveyor support to prevent the device from shifting during operation.

[0081] The first limiting mechanism 2 is located below the first fixing mechanism 1 and is fixedly connected to the first fixing mechanism 1. The first fixing mechanism 1 is used to fix the first limiting mechanism 2. The first limiting mechanism 2 is a component used to fix and limit the movement of the first installation mechanism 4 to prevent the first installation mechanism 4 from shifting laterally during lifting or jacking, and to ensure that the temporary roller 9 is installed in a precise position.

[0082] The first lifting mechanism 3 is located outside the first fixing mechanism 1. The first lifting mechanism 3 is a power component that drives the first mounting mechanism 4 to move in the vertical direction. It is used to adjust the height of the first mounting mechanism 4, thereby driving the temporary idler roller 9 on the mounting base 41 to rise and fall. During operation, the temporary idler roller 9 can accurately fit the lower surface of the conveyor belt to achieve temporary support for the conveyor belt.

[0083] The first mounting mechanism 4 is provided on the first lifting mechanism 3, and the first mounting mechanism 4 passes through the first limiting mechanism 2. The first lifting mechanism 3 is used to lift the first mounting mechanism 4, and the first limiting mechanism 2 is used to limit the first mounting mechanism 4. The first mounting mechanism 4 is a component used to place one end of the temporary roller 9, providing stable support for the temporary roller 9, and at the same time cooperating with the first lifting mechanism 3 to adjust the height of the temporary roller 9.

[0084] The second fixing mechanism 5 is fixedly installed on the other side of the belt conveyor's support, and the second fixing mechanism 5 is arranged opposite to the first fixing mechanism 1;

[0085] The second limiting mechanism 6 is disposed below the second fixing mechanism 5. The second limiting mechanism 6 is fixedly connected to the second fixing mechanism 5. The second limiting mechanism 6 is disposed opposite to the first limiting mechanism 2. The second fixing mechanism 5 is used to fix the second limiting mechanism 6.

[0086] The second lifting mechanism 7 is located outside the second fixing mechanism 5;

[0087] The second installation mechanism 8, the second limiting mechanism 6 is disposed on the second lifting mechanism 7, and the second installation mechanism 8 passes through the second limiting mechanism 6. The second lifting mechanism 7 is used to lift the second installation mechanism 8, and the second limiting mechanism 6 is used to limit the second installation mechanism 8.

[0088] The second fixing mechanism 5, the second limiting mechanism 6, the second lifting mechanism 7, and the second mounting mechanism 8 have the same structure and function as the first fixing mechanism 1, the first limiting mechanism 2, the first lifting mechanism 3, and the first mounting mechanism 4, except that they are symmetrically arranged on the other side of the belt conveyor support, together forming the symmetrical support structure of the device. The second fixing mechanism 5 is fixedly installed on the other side of the belt conveyor support, opposite to the first fixing mechanism 1; the second limiting mechanism 6 is located below the second fixing mechanism 5, fixedly connected to the second fixing mechanism 5, and opposite to the first limiting mechanism 2; the second lifting mechanism 7 is located outside the second fixing mechanism 5; the second mounting mechanism 8 passes through the second limiting mechanism 6 and is installed on the second lifting mechanism 7; its specific structural details are exactly the same as the first group of mechanisms, and will not be repeated here. The symmetrical design allows the device to support the temporary idler roller 9 from both sides of the conveyor belt support simultaneously, ensuring that the temporary idler roller 9 is subjected to uniform force and avoiding tilting of the temporary idler roller 9 due to support on one side. At the same time, the height of the two side mechanisms can be adjusted independently to adapt to scenarios where there are slight differences in height on both sides of the conveyor belt support (such as support deformation after long-term use), further improving the adaptability of the device. The symmetrical structure also allows the device to only need to adjust the spacing of the two side mounting mechanisms when changing idler rollers of different lengths, without having to replace the entire component, reducing equipment investment costs.

[0089] A temporary idler roller 9 is also included. One end of the temporary idler roller 9 is placed on the first mounting mechanism 4, and the other end is placed on the second mounting mechanism 8. The first mounting mechanism 4 and the second mounting mechanism 8 cooperate to place the temporary idler roller 9. The temporary idler roller 9 is a core component that replaces the lower idler roller in supporting the empty section of the conveyor belt during the removal of the faulty idler roller, ensuring that the conveyor belt operates without interruption. In this embodiment, the length of the temporary idler roller 9 is the same as that of the lower idler roller, completely covering the support area of ​​the empty section of the conveyor belt, preventing local sagging and deformation of the conveyor belt, and ensuring normal material transport.

[0090] Optionally, in some embodiments, such as Figures 1 to 5 As shown, both the first fixing mechanism 1 and the second fixing mechanism 5 include a fixing slot 11, an upper fixing component 12, and a lower fixing component 13. The upper fixing component 12 is disposed at the top of the fixing slot 11, and the lower fixing component 13 is disposed at the bottom of the fixing slot 11. The first limiting mechanism 2 is fixedly connected to the fixing slot 11, and the second limiting mechanism 6 is fixedly connected to the fixing slot 11. The upper fixing component 12 and the lower fixing component 13 cooperate with each other to fix the fixing slot 11 to the belt conveyor bracket. In this embodiment, the fixing slot 11 has a "U-shaped" groove structure with the groove opening facing the belt conveyor bracket to wrap around the edge of the bracket. The upper fixing component 12 and the lower fixing component 13 are bolt and nut structures.

[0091] Optionally, in some embodiments, such as Figures 1 to 5 As shown, the top of the fixing slot 11 is provided with an upper fixing hole 14, and the bottom of the fixing slot 11 is provided with a lower fixing hole 15; the upper fixing component 12 passes through the upper fixing hole 14 and is threadedly connected to the fixing slot 11; the lower fixing component 13 passes through the lower fixing hole 15 and is threadedly connected to the fixing slot 11. Specifically, in this embodiment, as... Figures 1 to 5 As shown, the top of the fixing slot 11 is provided with an upper fixing hole 14, which is a threaded hole with a diameter that matches the upper fixing component 12. The upper fixing component 12 is a bolt and nut structure, which passes through the upper fixing hole 14 and is connected to the fixing slot 11 by threads. The bottom end of the bolt is provided with a rubber pad, which fits tightly against the upper surface of the bracket when tightened, enhancing the fixing stability. The bottom of the fixing slot 11 is provided with a lower fixing hole 15, which is also a threaded hole. The lower fixing component 13 is a bolt and nut structure, which passes through the lower fixing hole 15 and is connected to the fixing slot 11 by threads. The end of the bolt is also provided with a rubber pad, which fits against the lower surface of the bracket when tightened, forming a "clamping" fixing effect with the upper fixing component 12.

[0092] Optionally, in some embodiments, such as Figures 1 to 5 As shown, the upper fixing hole 14 is located on the outer side of the top of the fixing slot 11, and the lower fixing hole 15 is located on the inner side of the bottom of the fixing slot 11. This layout can prevent the upper fixing component 12 and the lower fixing component 13 from interfering with each other during installation, while enhancing the fit between the fixing slot 11 and the bracket.

[0093] Optionally, in some embodiments, such as Figures 1 to 5 As shown, there are two upper fixing holes 14, which are spaced apart and opposite to each other. There are also two upper fixing components 12, which are spaced apart and opposite to each other. Similarly, there are two lower fixing holes 15, which are spaced apart and opposite to each other. There are also two lower fixing components 13, which are spaced apart and opposite to each other. The two upper fixing components 12 and the two lower fixing components 13 are installed correspondingly to ensure that the fixing force is evenly distributed on both sides of the bracket, preventing the fixing groove 11 from deforming due to uneven force. Specifically, in this embodiment, as... Figures 1 to 5 As shown, the structure of "fixed slot 11 and upper fixing component 12 and lower fixing component 13" enables a quick and stable connection between the device and the belt conveyor support; the design of double fixing holes and double fixing components further improves the fixing stability, increases the clamping force, and meets the structural strength requirements for non-stop operation.

[0094] Optionally, in some embodiments, such as Figures 1 to 5As shown, both the first limiting mechanism 2 and the second limiting mechanism 6 include a first limiting plate 21 and a second limiting plate 22. The top of the first limiting plate 21 is fixedly connected to the bottom of the fixed slot 11, and the top of the second limiting plate 22 is fixedly connected to the bottom of the fixed slot 11. Both the first limiting plate 21 and the second limiting plate 22 are rectangular steel plates, and their tops are welded to the bottom of the fixed slot 11 to form an integrated structure. The first limiting plate 21 and the second limiting plate 22 are spaced apart and opposite to each other, with a gap between them. The width of this gap is adapted to the thickness of the first mounting mechanism 4 to allow the first mounting mechanism 4 to pass through. Through the gap formed by the first limiting plate 21 and the second limiting plate 22, the lateral movement of the first mounting mechanism 4 can be precisely limited, ensuring that the first mounting mechanism 4 can only move up and down in the vertical direction, avoiding the first mounting mechanism 4 from shifting due to conveyor belt vibration, thereby ensuring that the temporary idler roller 9 is always in the correct position supporting the conveyor belt.

[0095] Optionally, in some embodiments, such as Figures 1 to 5 As shown, both the first lifting mechanism 3 and the second lifting mechanism 7 include a fixed cylinder 31, a screw 32, and a fixing nut 33. The fixed cylinder 31 is fixedly disposed on the outside of the fixing slot 11. The fixed cylinder 31 is a cylindrical steel pipe. One end of the screw 32 passes through the fixed cylinder 31 from top to bottom. The mounting seat 41 of the first mounting mechanism 4 is disposed on the other end of the screw 32, and the mounting seat 41 of the second mounting mechanism 8 is disposed on the other end of the screw 32. The fixing nut 33 is disposed on the other end of the screw 32. The fixing nut 33 is threadedly connected to the screw 32. The fixing nut 33 is located below the mounting seat 41 of the first mounting mechanism 4 and below the saddle of the second mounting mechanism 8. Tightening the fixing nut 33 locks the position of the screw 32 and the first mounting mechanism 4. The screw 32 adjusts the height of the mounting base 41 of the first mounting mechanism 4, thereby raising and lowering the temporary idler roller 9 on the mounting base 41. During operation, the temporary idler roller 9 precisely conforms to the lower surface of the conveyor belt, providing temporary support. The mechanical transmission method using the screw 32 is simple in structure and low in cost, requiring no external power source, making it suitable for operation scenarios without air or electricity. Precise height adjustment can be achieved through the cooperation of the screw 32 and the fixing nut 33.

[0096] Optionally, in some other embodiments, such as Figures 1 to 5As shown, both the first lifting mechanism 3 and the second lifting mechanism 7 are hydraulic cylinders, pneumatic cylinders, or electric cylinders. Specifically, one end of the hydraulic cylinder, pneumatic cylinder, or electric cylinder is fixed to the outside of the fixing slot 11, and the other end of the hydraulic cylinder, pneumatic cylinder, or electric cylinder is connected to the mounting base 41. By adjusting the height of the mounting base 41 of the first mounting mechanism 4 using the hydraulic cylinder, pneumatic cylinder, or electric cylinder, the temporary idler roller 9 on the mounting base 41 is driven to rise and fall. During operation, the temporary idler roller 9 can accurately fit against the lower surface of the conveyor belt, thereby achieving temporary support for the conveyor belt.

[0097] Optionally, in some embodiments, such as Figures 1 to 5 As shown, both the first mounting mechanism 4 and the second mounting mechanism 8 include a mounting base 41. The mounting base 41 passes through the gap between the first limiting plate 21 and the second limiting plate 22 and connects to the first lifting mechanism 3; the mounting base 41 also passes through the gap between the first limiting plate 21 and the second limiting plate 22 and connects to the second lifting mechanism 7. The mounting base 41 is a rectangular steel plate, passing through the gap between the first limiting plate 21 and the second limiting plate 22 and connecting to the screw 32. The two sides of the mounting base 41 are fitted against the inner sides of the gap between the first limiting plate 21 and the second limiting plate 22, allowing it to slide vertically along the gap to achieve lifting movement. The cooperation between the mounting base 41 and the limiting mechanism further ensures stability during the lifting process and ensures accurate height adjustment of the temporary idler roller 9.

[0098] Optionally, in some embodiments, such as Figures 1 to 5 As shown, both the first mounting mechanism 4 and the second mounting mechanism 8 further include a mounting groove 42, which is disposed on the mounting base 41. The mounting groove 42 is formed on the upper surface of the mounting base 41 and is a U-shaped groove, with a rubber anti-slip pad adhered inside. The mounting groove 42 allows for precise positioning of the temporary idler roller 9 shaft head, preventing axial displacement of the temporary idler roller 9 during operation. The rubber anti-slip pad not only enhances the friction between the temporary idler roller 9 and the mounting groove 42, preventing slippage, but also buffers the impact of conveyor belt vibration on the temporary idler roller 9, extending its service life.

[0099] Specifically, the working principle of the device for replacing the lower idler roller of the belt conveyor in this embodiment is as follows:

[0100] 1. Fix the first fixing mechanism 1 and the second fixing mechanism 5 on both sides: The operator will clamp the fixing slot 11 of the first fixing mechanism 1 onto the left edge of the belt conveyor bracket, tighten the upper fixing component 12 and the lower fixing component 13, so that the rubber pad is tightly attached to the surface of the bracket, and the left side mechanism is fixed; similarly, fix the second fixing mechanism 5 on the right edge of the bracket to ensure that the two sides are symmetrical.

[0101] 2. Install temporary idler roller 9: Place one end of the roller shaft of temporary idler roller 9 into the mounting groove 42 of the first mounting mechanism 4, and the other end into the mounting groove 42 of the second mounting mechanism 8. Confirm that temporary idler roller 9 is placed stably and without axial displacement.

[0102] 3. Adjusting the height of temporary idler roller 9: If a mechanical transmission lifting mechanism is used, the operator rotates the screw 32 of the first lifting mechanism 3 and the second lifting mechanism 7 to drive the first mounting mechanism 4 and the second mounting mechanism 8 to rise until the roller body of the temporary idler roller 9 is in close contact with the lower surface of the conveyor belt. Then, raise it another 5-10 cm to create a 5-10 cm height difference between the idler roller to be replaced and the lower surface of the conveyor belt. Stop rotating when replacing the idler roller. If a power-driven lifting mechanism is used, the piston rod of the cylinder / hydraulic cylinder is extended by controlling the control valve to adjust the height of the temporary idler roller 9 to be in contact with the conveyor belt. Then, raise it another 5-10 cm to create a 5-10 cm height difference between the idler roller to be replaced and the lower surface of the conveyor belt. Stop rotating when replacing the idler roller. Close the control valve to lock the position.

[0103] 4. Disassembling the faulty lower idler: After the temporary idler 9 supports the conveyor belt, the operator uses a wrench to remove the bearing seat bolts at both ends of the faulty lower idler and remove the faulty lower idler from the bracket (because the temporary idler 9 has already supported the conveyor belt, the belt conveyor can operate normally during the disassembly process).

[0104] 5. Install the new lower idler roller: Align the shaft ends of the new lower idler roller with the bearing housing mounting holes on the bracket, insert them and tighten the bearing housing bolts, and confirm that the new lower idler roller can rotate freely (without jamming or abnormal noise).

[0105] 6. Remove temporary idler roller 9: After the new lower idler roller is installed, adjust the first lifting mechanism 3 and the second lifting mechanism 7 to lower the first mounting mechanism 4 and the second mounting mechanism 8, so that the temporary idler roller 9 is separated from the conveyor belt. Remove the temporary idler roller 9 from the first mounting mechanism 4 and the second mounting mechanism 8. Finally, disassemble the fixing components of the first fixing mechanism 1 and the second fixing mechanism 5, remove the device from the bracket, and complete the replacement operation.

[0106] Specifically, the device for replacing the lower idler roller of the belt conveyor in this embodiment has the following beneficial effects:

[0107] 1. Achieve non-stop replacement: By replacing the faulty idler with a temporary idler 9, the conveyor belt can continue to operate during the replacement process, completely avoiding production losses caused by downtime and improving production efficiency (taking a paper mill as an example, each replacement can save more than 1 hour of downtime, saving more than 100,000 yuan in annual production capacity loss).

[0108] 2. Convenient and efficient operation: The device adopts a modular design, with installation and disassembly time ≤10 minutes and total replacement time of a single lower idler roller ≤15 minutes, which improves efficiency by 2-4 times compared to traditional downtime maintenance; ordinary operators can operate it proficiently after 1 hour of training, without the need for professional maintenance personnel.

[0109] 3. High adaptability: With adjustable first fixing mechanism 1, second fixing mechanism 5 and replaceable temporary idler roller 9, it covers more than 90% of the belt conveyor specifications in paper mills, with high adaptability and no need to customize special equipment.

[0110] Finally, it should be noted that although the above embodiments have been described in the text and drawings of this application, this should not limit the scope of patent protection of this application. Any technical solutions that are based on the essential concept of this application and utilize the content described in the text and drawings of this application, resulting in equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this application.

Claims

1. A device for replacing the lower idler roller of a belt conveyor, characterized in that, include: The first fixing mechanism is fixedly installed on one side of the belt conveyor's support frame; A first limiting mechanism is disposed below the first fixing mechanism and is fixedly connected to the first fixing mechanism. The first fixing mechanism is used to fix the first limiting mechanism. A first lifting mechanism is disposed outside the first fixed mechanism; A first installation mechanism, wherein the first limiting mechanism is disposed on the first lifting mechanism and the first installation mechanism passes through the first limiting mechanism, the first lifting mechanism is used to lift the first installation mechanism, and the first limiting mechanism is used to limit the first installation mechanism; The second fixing mechanism is fixedly installed on the other side of the belt conveyor's support frame, and the second fixing mechanism is arranged opposite to the first fixing mechanism; The second limiting mechanism is disposed below the second fixing mechanism. The second limiting mechanism is fixedly connected to the second fixing mechanism. The second limiting mechanism is disposed opposite to the first limiting mechanism. The second fixing mechanism is used to fix the second limiting mechanism. The second lifting mechanism is located outside the second fixing mechanism; The second installation mechanism is provided on the second lifting mechanism, and the second installation mechanism passes through the second limiting mechanism. The second lifting mechanism is used to lift the second installation mechanism, and the second limiting mechanism is used to limit the second installation mechanism. And a temporary idler roller, one end of which is placed on the first mounting mechanism and the other end of which is placed on the second mounting mechanism. The first mounting mechanism and the second mounting mechanism cooperate with each other to place the temporary idler roller.

2. The device for replacing the lower idler roller of a belt conveyor according to claim 1, characterized in that: Both the first fixing mechanism and the second fixing mechanism include a fixing slot, an upper fixing component, and a lower fixing component; The upper fixing component is disposed at the top of the fixing slot, and the lower fixing component is disposed at the bottom of the fixing slot; The first limiting mechanism is fixedly connected to the fixed slot, and the second limiting mechanism is fixedly connected to the fixed slot; The upper fixing component and the lower fixing component cooperate with each other to fix the fixing slot to the bracket of the belt conveyor.

3. The device for replacing the lower idler roller of a belt conveyor according to claim 2, characterized in that: The top of the fixing slot is provided with an upper fixing hole, and the bottom of the fixing slot is provided with a lower fixing hole; The upper fixing component passes through the upper fixing hole and is connected to the fixing slot by a thread; The lower fixing component passes through the lower fixing hole and is connected to the fixing slot by a thread.

4. The device for replacing the lower idler roller of a belt conveyor according to claim 3, characterized in that: The upper fixing hole is located on the outer side of the top of the fixing slot, and the lower fixing hole is located on the inner side of the bottom of the fixing slot.

5. The device for replacing the lower idler roller of a belt conveyor according to claim 3, characterized in that: There are two upper fixing holes, which are arranged opposite to each other at a distance; there are two upper fixing components, which are arranged opposite to each other at a distance. There are two lower fixing holes, which are arranged opposite each other at a distance. There are two lower fixing components, which are arranged opposite each other at a distance.

6. The device for replacing the lower idler roller of a belt conveyor according to claim 2, characterized in that: Both the first limiting mechanism and the second limiting mechanism include a first limiting plate and a second limiting plate; The top of the first limiting plate is fixedly connected to the bottom of the fixing slot, and the top of the second limiting plate is fixedly connected to the bottom of the fixing slot. The first limiting plate and the second limiting plate are arranged opposite each other at a distance, and a gap is left between the first limiting plate and the second limiting plate.

7. The device for replacing the lower idler roller of a belt conveyor according to claim 2, characterized in that: Both the first lifting mechanism and the second lifting mechanism include a fixed cylinder, a screw, and a fixing nut; The fixing cylinder is fixedly disposed on the outside of the fixing slot; One end of the screw passes through the fixed cylinder from top to bottom, the first mounting mechanism is disposed at the other end of the screw, and the second mounting mechanism is disposed at the other end of the screw; The fixing nut is disposed on the other end of the screw, and the fixing nut is connected to the screw by a thread. The fixing nut is located below the first mounting mechanism and the fixing nut is disposed below the second mounting mechanism.

8. The device for replacing the lower idler roller of a belt conveyor according to claim 1, characterized in that: Both the first lifting mechanism and the second lifting mechanism are hydraulic cylinders, pneumatic cylinders, or electric cylinders.

9. The device for replacing the lower idler roller of a belt conveyor according to claim 6, characterized in that: Both the first installation mechanism and the second installation mechanism include a mounting base, and the mounting base passes through the gap between the first limiting plate and the second limiting plate and is connected to the first lifting mechanism; The mounting base passes through the gap between the first limiting plate and the second limiting plate and connects to the second lifting mechanism.

10. The device for replacing the lower idler roller of a belt conveyor according to claim 9, characterized in that: Both the first mounting mechanism and the second mounting mechanism further include a mounting groove, which is disposed on the mounting base.

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