A high-efficiency and energy-saving roller

Abstract

The present invention discloses a high-efficiency and energy-saving roller, comprising a roller body, bearing seats placed at both ends of the roller body, shafts placed in the shaft holes of the two bearing seats, bearings and a kit placed in the bearing seats, wherein the bearing seats comprise a cylindrical bearing seat body and a rib connected to the bearing seat body, wherein the maximum diameter of the rib is larger than the inner diameter of the two ends of the roller body; the inner diameters of the two ends of the roller body are equal and coaxial, and the rib is provided with a positioning section with a gradually changing outer diameter, wherein the center of the outer surface of the positioning section along any radial section of the bearing seat is coaxial with the shaft hole. When ensuring coaxiality, there is no need to provide a bearing hole for limiting and fixing the bearing seat in the roller body, and the roller body can adopt a uniform wall thickness structure, that is, the entire roller body can adopt the wall thickness corresponding to the existing bearing hole, which greatly reduces the material consumption of the roller body, reduces the weight of the roller body, and saves costs; and can greatly improve the manufacturing efficiency of the roller; when driving the roller to rotate, it can reduce the running resistance, reduce the driving power, and save running energy consumption.

Description

Technical Field

[0001] The present invention relates to the field of rollers, and more particularly to a high-efficiency and energy-saving roller. Background Art

[0002] Rollers, also known as drums, are widely used in various transmission and conveying systems, such as rotary screen printing machines, digital printers, mining conveying equipment, and papermaking and packaging machinery. Depending on their function, rollers can be divided into idler rollers and deflection rollers. Both idler rollers and deflection rollers are key components of belt conveyors. Their structures are derived from the industry design in the "Conveyor Machinery Design and Selection Manual" and are currently the common structural design used by professional belt conveyor manufacturers in China.

[0003] The existing roller body is an integral structure design, the roller body is seamless roller body, the roller body structure is detailed in Figure 1 , Application No. 201220012866.0 "A roller with a detachable and replaceable roller surface" and Application No. 201320314620.3 "A roller for an endless belt conveyor" have bearing holes at both ends of the roller body, and the bearing seats are placed in the bearing holes. The rollers using the existing structure have the following defects:

[0004] 1. The coaxiality of the bearing holes at both ends of the roller body can ensure the installation quality of the shaft. In order to ensure the coaxiality requirements of the bearing holes at both ends of the roller body, the other hole must be positioned and machined based on the machined hole, which increases the clamping and positioning process and difficulty, and seriously affects the coaxiality quality requirements of the roller body.

[0005] 2. With the existing structure, in order to ensure the thickness of the roller body at the bearing hole, the tube wall outside the bearing hole is thicker, the roller body is heavier, and the cost is high. Summary of the Invention

[0006] In order to solve the above technical problems, the present invention provides a high-efficiency and energy-saving roller.

[0007] The present invention is achieved through the following technical solutions:

[0008] A high-efficiency, energy-saving roller comprises a roller body, bearing seats positioned at either end of the roller body, shafts positioned within the axial holes of the two bearing seats, bearings positioned within the bearing seats, and a sleeve. The bearing seats comprise a cylindrical bearing seat body and a rib connected to the cylindrical opening of the bearing seat body. The rib has a maximum diameter greater than the inner diameter of the roller body at either end, and the inner diameters of the roller body at both ends are equal and coaxial. The rib is provided with a positioning segment with a gradually changing outer diameter. The center of the outer surface of the positioning segment, taken along any radial section of the bearing seat, is coaxial with the axial hole. It should be noted that the outer surface referred to in this solution refers to the side in contact with the roller body. The roller body and bearing seat structure of this solution eliminates the need for bearing holes within the roller body to limit and secure the bearing seat. The roller body can adopt a uniform wall thickness structure, meaning the entire roller body can adopt the wall thickness corresponding to the existing bearing holes. This significantly reduces the material usage of the roller body, reduces its weight, and saves costs. The outer diameter of the bearing seat body is smaller than the inner diameter of the roller body, facilitating the installation of the bearing seat. The positioning section is welded and positioned. When the bearing seat body is installed to the roller body, the outer ring of the positioning end simultaneously contacts the inner diameter surface of the roller body end face, ensuring the coaxiality of the bearing seats at both ends. This roller body and bearing seat structure eliminates the need for bearing holes within the roller body to limit and secure the bearing seat, significantly improving roller manufacturing efficiency.

[0009] Preferably, in order to facilitate the processing of the bearing seat, the outer side surface of the positioning section is a conical surface or an arc surface.

[0010] Preferably, in order to improve the installation quality and speed of the bearing seat, tapered holes are provided at both ends of the roller body, and the tapered holes are fitted with the tapered surface of the large end of the bearing seat for positioning. The setting of the tapered holes facilitates the installation of the bearing seat and ensures the coaxiality of the bearing seats at both ends, making it easier to install the bearing seat body into the roller body, thereby improving assembly accuracy and speed.

[0011] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0012] 1. The roller body of the present invention does not need to be provided with a bearing hole for limiting and fixing the bearing seat. The roller body can adopt a uniform wall thickness structure, that is, the entire roller body can adopt the wall thickness corresponding to the existing bearing hole, which greatly reduces the material consumption of the roller body, reduces the weight of the roller body, saves costs; and can greatly improve the production efficiency of the roller.

[0013] 2. The roller structure of this solution reduces the weight of the roller body. When the roller is driven to rotate, the running resistance can be reduced, the driving power can be reduced, and the operating energy consumption can be saved.

[0014] 3. The present invention provides a positioning section on the rib to realize the welding positioning of the bearing seat. The bearing seat body is installed to the roller body. The outer circle of the positioning end is in contact with the inner diameter surface of the roller body end face at the same time, ensuring the coaxiality of the bearing seats at both ends and improving the assembly accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The drawings described herein are used to provide a further understanding of the embodiments of the present invention, constitute a part of this application, and do not constitute a limitation of the embodiments of the present invention.

[0016] Figure 1 It is a structural diagram of the existing roller body.

[0017] Figure 2 This is a schematic diagram of the structure of the pipe body of this scheme.

[0018] Figure 3 This is a structural diagram of the bearing seat of this scheme.

[0019] Figure 4 This is a schematic diagram of the specific structure of Example 2.

[0020] Figure 5 This is a schematic diagram of the specific structure of Example 3.

[0021] Figure 6 This is a schematic diagram of a specific roller made using the structure of Example 3.

[0022] Figure 7 This is a schematic diagram of the roller body structure of this scheme. DETAILED DESCRIPTION

[0023] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with examples and drawings. The exemplary embodiments of the present invention and their descriptions are only used to explain the present invention and are not intended to limit the present invention.

[0024] Example 1

[0025] like Figures 2 to 5 The high-efficiency and energy-saving roller shown in the figure includes a roller body 1, a bearing seat 2, a shaft 3, a bearing 4 and a kit. The bearing seats 2 are placed at both ends of the roller body. A shaft hole is set on the bearing seat. The shaft 3 is passed through the shaft holes of the bearing seats at both ends. The bearing 4 and the kit are placed in the bearing seats. Specifically, Figure 3As shown, the bearing seat comprises a cylindrical bearing seat body 21 and a rib 22 connected to the opening of the bearing seat body 21. The bearing seat body 21 comprises a barrel and a bottom, with an axial hole located at the bottom, coaxial with the barrel. To ensure the performance of the bearing seat, the bearing seat body 21 and the rib are integrally formed. The maximum diameter of the rib 22 is larger than the inner diameter of the roller barrel 1 at both ends. When fixed, the rib directly engages the ends of the roller barrel, and the ends of the roller barrel achieve the rib position limit. This eliminates the need for a step within the roller barrel, i.e., the bearing hole, to achieve rib position limit, thus eliminating the need for a bearing hole. The roller body can adopt an equal diameter and equal wall thickness structure, that is, a straight tube structure. The inner diameters at both ends of the roller body 1 are equal and coaxial. A positioning section with a gradually changing outer diameter is provided on the rib 22. The center of the outer side surface of the positioning section along any radial section of the bearing seat 2 is coaxial with the shaft hole. When welded and fixed, the inner diameter of the roller body end contacts the outer side surface of a section of the positioning section to achieve coaxial positioning, so as to ensure the coaxiality of the shaft holes of the bearing seats at both ends, that is, to ensure the coaxiality of the installation of the bearing 4.

[0026] Specifically, the outer side surface of the positioning segment can be set to a conical surface or an arc surface.

[0027] Example 2

[0028] Based on the principles and structures of the above embodiments, see Figure 4 , this embodiment discloses the application of its structure in a deflection-blocking roller.

[0029] See also Figure 4 The deflection-blocking roller consists of a roller body 1, a bearing seat 2, a shaft 3, a bearing 4, and a kit. The kit includes existing components such as retaining rings and seals. The bearing seats 2 are placed at both ends of the roller body. Shafts 3 are inserted into the holes in the bearing seats at both ends, and the bearings 4 and kit are placed inside the bearing seats. The maximum diameter of the ribs 22 of the bearing seats 2 at both ends of the roller body 1 is larger than the inner diameter of the roller body 1 and equal to the outer diameter of the roller body 1.

[0030] The bearing seat includes a cylindrical bearing seat body 21 and a rib 22 connected to the bearing seat body 21. The outer side of the rib is provided with a conical surface. The conical surface of the large end of the cylindrical body of the bearing seat body 21 and the 4×10° tapered holes at both ends of the roller body are fitted and positioned. Figure 7 , ensuring the coaxiality of the bearing seats at both ends.

[0031] Example 3

[0032] Based on the principle and structure of Example 1, see Figure 5 , this embodiment discloses the application of its structure in a roller.

[0033] See also Figure 5The deviation-blocking roller includes a roller body 1, a bearing seat 2, a shaft 3, a bearing 4 and a kit. The kit includes existing components such as a retaining ring 72 and a seal 71. The bearing seat 2 is placed at both ends of the roller body. An axial hole is set on the bearing seat. The shaft 3 is passed through the axial holes of the bearing seats at both ends. The bearing 4 and the kit are placed in the bearing seat. A rubber ring 5 is arranged on the outer surface of the roller body 1; the maximum diameter of the retaining edge 22 of the bearing seat at one end of the roller body 1 is larger than the outer diameter of the roller body 1 to constitute a limit for one end of the rubber ring. Specifically, a limit section is set on the retaining edge 22, and the maximum diameter of the limit section is larger than the outer diameter of the roller body 1 to realize the limit of the rubber ring; the maximum diameter of the retaining edge 22 of the bearing seat at the other end of the roller body 1 is equal to the outer diameter of the roller body 1 to facilitate the installation of the rubber ring. A retaining ring 6 is fixed at this end of the roller body 1 to constitute a limit for the other end of the rubber ring 5.

[0034] Similarly, the bearing seat includes a cylindrical bearing seat body 21 and a rib 22 connected to the bearing seat body 21. The outer side of the rib is provided with a conical surface or an arc surface. The cylindrical conical surface of the bearing seat body 21 and the 4×10° tapered holes at both ends of the roller body are fitted and positioned to ensure the coaxiality of the bearing seats at both ends of the roller body.

[0035] The existing roller specifications are generally Ф60, Ф89, Ф108, Ф133, Ф159, etc. Figure 6 、 Figure 7 The Ф60×3.2 shown illustrates the structure of this solution and its advantages.

[0036] The roller body 1 and the bearing seat 2 can be automatically welded on the double-head carbon dioxide gas shielded welding machine of the roller production line. The bearing seats 2 at both ends of the roller body 1 are made of Figure 2 After the welding is completed on the right side, the left side bearing seat is processed into Figure 2 The structure shown in the figure completes the production of the high-efficiency and energy-saving roller tube body; then the shaft, bearing, kit, rubber ring, retaining ring and other structures are installed in sequence.

[0037] From the roller body, the Figure 1 The existing structure shown in the figure uses 3.11 kg of material for the roller body. However, the structure of this embodiment uses only 1.19 kg of material for the roller body and 0.5 kg of material for the bearing seat, which greatly saves material.

[0038] In terms of processing efficiency, using the existing structure, cutting + turning the bearing seat hole takes 5 minutes + 12 minutes, a total of 17 minutes; however, using the structure of this embodiment, cutting + turning the tapered surface + turning the ribs at both ends of the bearing seat takes 2.5 minutes + 3 minutes + 2 minutes, a total of 7.5 minutes, which greatly saves nearly 60% of the work efficiency.

[0039] Regarding the energy consumption of belt conveyor buffer rollers, the conveyor's operating energy consumption is proportional to the mass of the roller's rotating components. The greater the mass of the rotating component, the greater the operating resistance, and the greater the motor power required for normal conveyor operation. For both existing and present embodiments, assuming the same rubber rings, bearings, and seals, the operating resistance is primarily determined by the roller's design weight. Ignoring the mass of the roller's bearings and rotating seals, the conventional roller's operating resistance is approximately 0.76N. With the present embodiment, the roller's operating resistance is approximately 0.17N, saving approximately 78% of operating energy.

[0040] The specific implementation methods described above further illustrate the objectives, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above description is only a specific implementation method of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A high-efficiency energy-saving roller, comprising a roller body (1), bearing seats (2) disposed at both ends of the roller body (1), shafts (3) disposed in shaft holes of the two bearing seats (2), bearings (4) both disposed in the bearing seats (2), and a kit, wherein the bearing seat comprises a cylindrical bearing seat body (21), a shaft hole disposed on the bearing seat body (21) for sleeve-mounting the shaft (3), and a rib (22) connected to the barrel opening of the bearing seat body (21), characterized in that: The maximum diameter of the rib (22) is larger than the inner diameter of both ends of the roller body (1); The inner diameters of the two ends of the roller body (1) are equal and coaxial, and the retaining edge (22) is provided with a positioning section with a gradually changing outer diameter, and the center of the outer side surface of the positioning section along any radial section of the bearing seat (2) is coaxial with the axial hole; the outer side surface of the positioning section is a conical surface; the two ends of the roller body (1) are provided with conical holes, and the conical holes are fitted with the large end conical surface of the bearing seat body (21); the retaining edge (22) also includes a limiting section, and the maximum diameter of the limiting section is greater than or equal to the outer diameter of the roller body (1).

2. The high-efficiency energy-saving roller according to claim 1, characterized in that: The roller body (1) is provided with a rubber ring (5) on its outer surface; the maximum diameter of the retaining edge (22) of the bearing seat at one end of the roller body (1) is larger than the outer diameter of the roller body (1), and the maximum diameter of the retaining edge (22) of the bearing seat at the other end is equal to the outer diameter of the roller body (1), and a retaining ring (6) for limiting the rubber ring (5) is fixed to this end of the roller body (1).

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