A noise reduction idler for a belt conveyor

Abstract

The belt conveyor noise reduction carrier roller comprises a roller body, a roller shaft, a bearing and a bearing seat, and further comprises an inner noise reduction assembly and an outer noise reduction assembly; the inner noise reduction assembly is used for noise reduction treatment of noise between the bearing seat and the bearing, and comprises a noise reduction ring which is arranged between the inner wall of the bearing seat and the bearing; a plurality of channels are arranged in the noise reduction ring, and sound absorbing members are arranged in the channels; the outer noise reduction assembly is used for noise reduction treatment of noise between the roller body and a conveying belt, a plurality of exhaust channels are formed in the side wall of the roller body, the outer noise reduction assembly comprises a plurality of gaskets which are fixedly connected to the outer side wall of the roller body, the plurality of gaskets are in one-to-one correspondence with and communicate with the plurality of exhaust channels, a plurality of air bags are fixedly arranged on the inner side wall of the roller body, and the plurality of air bags are in one-to-one correspondence with and communicate with the plurality of exhaust channels; and the inner noise reduction assembly and the outer noise reduction assembly jointly reduce noise generated during belt operation and roller operation.

Description

Technical Field

[0001] This invention relates to the field of belt conveyor technology, and in particular to a noise-reducing idler roller for belt conveyors. Background Technology

[0002] Belt conveyors are a type of high-efficiency continuous transportation equipment that utilizes the friction between materials and belts to achieve transport. They can meet requirements such as long transport distance, large transport capacity, large inclination angle, and continuous transport. Moreover, the equipment system can achieve centralized management and control, and has been widely used in industries such as mining, ports, metallurgy, and chemicals.

[0003] Idler rollers are mainly used to support the conveyor belt on belt conveyors, allowing the conveyor belt to run smoothly along a predetermined direction. In existing technology, idler rollers typically consist of a roller body, roller shaft, bearings, and bearing housings. During conveyor operation, the rotation of the idler rollers causes vibration between the bearings and bearing housings, and the airflow generated when the idler rollers contact the conveyor belt causes wind noise, resulting in significant noise levels during conveyor operation. Current technologies for noise reduction of idler rollers typically reduce vibration noise between metal components by changing the material, but this has significant limitations. For specific environments, parts made of metal are still required. Furthermore, existing technologies do not address the noise problem caused by windflow when the idler rollers contact the conveyor belt. Summary of the Invention

[0004] In view of the above-mentioned shortcomings, the present invention proposes a noise-reducing idler roller for belt conveyors.

[0005] A noise-reducing idler roller for a belt conveyor includes a roller body, a roller shaft, a bearing, and a bearing housing. The bearing housing is installed at both ends of the roller body, the bearing is installed within the bearing housing, and the roller shaft is installed within the bearing and passes through the roller body. The roller body is characterized by further comprising: an inner noise-reducing component and an outer noise-reducing component. The inner noise-reducing component is disposed between the inner wall of the bearing housing and the bearing, and is used to reduce noise between the bearing housing and the bearing. The inner noise-reducing component includes a noise-reducing ring disposed between the inner wall of the bearing housing and the bearing, with several channels spaced apart inside the noise-reducing ring, and sound-absorbing elements disposed within the channels. The outer noise-reducing component is disposed on the outer wall of the roller body, and is used to reduce noise between the roller body and the conveyor belt. Several exhaust channels are formed on the side wall of the roller body. The outer noise-reducing component includes several washers fixedly connected to the outer wall of the roller body, with each washer corresponding to and communicating with one of the exhaust channels. Several airbags are fixedly disposed on the inner wall of the roller body, with each airbag corresponding to and communicating with one of the exhaust channels.

[0006] Compared with the prior art, the present invention has the following advantages and technical effects:

[0007] 1. The noise-reducing idler roller provided by the present invention achieves noise reduction treatment between the bearing and the bearing housing through the set internal noise reduction component, absorbs the generated vibration noise, and reduces the vibration noise between the bearing and the bearing housing during the use of the idler roller.

[0008] 2. The external noise reduction components are designed to reduce the wind pressure noise generated when the rollers and conveyor belt come into contact, thus further ensuring the overall noise reduction effect.

[0009] 3. The buffer section further reduces the vibration amplitude of the roller shaft, thereby reducing the vibration amplitude between the bearing and bearing housing on the roller shaft, and further reducing the vibration noise between the bearing and bearing housing during the use of the idler roller. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0011] Figure 2 For the present invention Figure 1 Enlarged view of a portion of point A in the middle;

[0012] Figure 3 For the present invention Figure 1 Enlarged view of a section at point B in the middle;

[0013] Figure 4 For the present invention Figure 1 Enlarged view of a section at point C;

[0014] Figure 5 This is a schematic diagram of the internal noise reduction component.

[0015] Figure 6 for Figure 5 A cross-sectional view of the sound-absorbing component along the axial direction.

[0016] Figure 7 This is a schematic diagram of another embodiment of washer 61.

[0017] The components include: roller body 10, exhaust channel 11, roller shaft 20, bearing 30, bearing seat 40, noise reduction ring 51, sound-absorbing component 52, tube body 53, sound-absorbing material 54, washer 61, air bag 62, elastic component 63, support frame 71, first connecting rod 711, second connecting rod 712, ring component 713, outer sleeve 72, outer rod 73, roller 74, inner sleeve 75, inner rod 76, sealing head 77, and inner spring 78. Detailed Implementation

[0018] See Figure 1-7This invention proposes a noise-reducing idler roller for a belt conveyor, comprising a roller body 10, a roller shaft 20, a bearing 30, and a bearing housing 40. The bearing housing 40 is installed at both ends of the roller body 10. The bearing 30 is installed within the bearing housing 40, and the roller shaft 20 is installed within the bearing 30 and passes through the roller body 10. The roller body 10 also includes an inner noise-reducing component and an outer noise-reducing component. The inner noise-reducing component is disposed between the inner wall of the bearing housing 40 and the bearing 30, and is used to reduce noise between the bearing housing 40 and the bearing 30. The inner noise-reducing component includes a noise-reducing ring 51, which is disposed between the inner wall of the bearing housing 40 and the bearing 30. Between the bearings 30, several channels are spaced apart inside the noise reduction ring 51, and sound-absorbing components 52 are installed in the channels; the external noise reduction assembly is installed on the outer wall of the roller body 10 to reduce the noise between the roller body 10 and the conveyor belt. Several exhaust channels 11 are opened on the side wall of the roller body 10. The external noise reduction assembly includes several washers 61 fixedly connected to the outer wall of the roller body 10. The several washers 61 correspond one-to-one with the several exhaust channels 11 and are connected. Several airbags 62 are fixedly installed on the inner wall of the roller body 10. The several airbags 62 correspond one-to-one with the several exhaust channels 11 and are connected.

[0019] Furthermore, an elastic element 63 is provided inside the roller body 10. The elastic element 63 is located on both sides of the airbag 62, with one end of the elastic element 63 fixed in position and the other end in elastic contact with the airbag 62. The elastic element 63 can be a spring. When the belt passes the washer 61, the airflow enters the airbag 62 from the washer 61 and the exhaust channel 11, inflating the airbag 62. When the belt leaves, the air pressure inside the airbag 62 is greater than the external air pressure. Combined with the restoring deformation potential energy of the airbag 62, the gas inside the airbag 62 is squeezed outward, and the airbag 62 returns to its original shape. By guiding the airflow brought by the belt into the airbag 62 for short-term storage, the noise caused by gas compression due to the lack of outlet for gas between the belt and the outer wall of the roller body 10 is avoided. After the gas is introduced into the airbag 62, the spring squeezes to accelerate the gas discharge, preparing for the next gas entry.

[0020] Furthermore, washer 61 has a notch at its opening. In the original design, the opening of washer 61 was a flat, circular cut. When in contact with the belt, it sometimes fits tightly, making separation difficult. Therefore, this design has a notch, which allows for a gap between the opening of washer 61 and the belt after contact, facilitating separation.

[0021] Furthermore, the noise reduction coil 51 is made of a deformable material. For example, it can be made of silicone, rubber, nylon, or fiber.

[0022] Furthermore, the sound-absorbing component 52 includes a hollow tube 53, the outer wall of which matches the inner wall of the channel, and the inner wall of which is curved. Sound-absorbing material 54 is disposed inside the tube 53. When the belt conveyor is operating normally, the roller speed can reach 60-100 rpm; the higher the speed, the greater the noise.

[0023] Furthermore, the sound-absorbing material 54 is a honeycomb-shaped flexible material, such as sound-absorbing cotton.

[0024] Furthermore, it also includes a buffer assembly, which includes a support frame 71, an outer sleeve 72, an outer rod 73, and a roller 74. The support frame 71 includes a first connecting rod 711 and a second connecting rod 712. One end of the first connecting rod 711 is fixedly connected to the inner wall of the roller body 10, and the other end is connected to an annular member 713. The annular member 713 is arranged around the outside of the roller shaft 20. The annular member 713 is separated from the roller shaft 20 by a pre-reserved gap to avoid friction. The second connecting rod 712 is connected between the two first connecting rods 711. Several outer sleeves 72 are fixedly arranged on the support frame 71. One end of the outer sleeve 72 is sealed and the other end is open. One end of the outer rod 73 is inserted into the inside of the outer sleeve 72, and the other end is connected to the roller 74. The roller 74 makes rolling contact with the roller shaft 20. Space is reserved inside the outer sleeve 72 for the outer rod 73 to move. This design addresses the deformation of the roller 10 under stress, preventing damage and deformation. When the roller 10 deforms, the support frame 71 deforms accordingly. This preload is transmitted to the second connecting rod 712, which in turn acts on the outer sleeve 72. The outer sleeve 72 compresses towards the roller shaft 20. The position of the inner outer sleeve rod 73 remains unchanged, but the space inside the outer sleeve 72 is compressed due to the unchanged position of the outer sleeve rod 73. This space compression forms a buffer, facilitating the release of the deformation force of the roller 10. The buffer assembly also forms a buffer connection between the roller 10 and the roller shaft 20. Compared to not setting a buffer assembly, or only setting a support frame 71 between the roller 10 and the roller shaft 20 (in both cases, the mechanical stress between the roller 10 and the roller shaft 20 cannot be released, resulting in high noise and easy mechanical damage to the roller shaft 20), this design not only releases the stress caused by deformation and reduces noise, but also helps protect the roller shaft 20.

[0025] Furthermore, an inner sleeve 75, an inner sleeve rod 76, and a sealing head 77 are also provided inside the outer sleeve 72. The sealing section of the inner sleeve 75 is fixedly connected to the inside of the outer sleeve 72. One end of the inner sleeve rod 76 is inserted into the inner sleeve 75, and the other end is fixedly connected to the outer sleeve rod 73. A space is reserved inside the inner sleeve 75. The sealing head 77 is located at the end of the inner sleeve rod 76 and seals the internal space of the inner sleeve 75, filling the internal space with air. The buffer assembly, which is integrally designed with the roller body 10, can withstand and transmit deformation force in the radial direction and is rolledly connected to the roller shaft 20. It can withstand deformation force in all directions of the circumference of the roller shaft 20, buffering and eliminating deformation force at any part of the roller body 10. The self-resetting of the outer sleeve 72, outer sleeve rod 73, inner sleeve 75, and inner sleeve rod 76 can also act on the inner wall of the roller body 10, causing it to reset after deformation and extending the service life of the roller body 10. The internal air filling serves to buffer the inner sleeve rod 76. The deformation force is released by compressing the air, and the inner sleeve rod 76 returns to its original position by releasing the air pressure. The air in this space plays a buffering role and replaces the noise caused by the sliding structure.

[0026] Furthermore, the buffer assembly also includes an inner spring 78.

[0027] To address the present invention, the noise of the idler roller during belt conveyor operation was tested at a distance of 1 meter from the idler roller. Three schemes were designed, and the data are as follows (Scheme 1: The roller design has neither internal nor external noise reduction components; Scheme 2: The roller design has both internal and external noise reduction components, and the inner wall of the tube 53 is flat; Scheme 3: The roller design has both internal and external noise reduction components, and the inner wall of the tube 53 is curved):

[0028] plan Rotational speed (rpm) Noise / decibel rotational speed Noise / decibel Increase / % Option 1 60 92 100 114 23.91％ Option 2 60 78 100 83 6.41％ Option 3 60 58 100 67 15.52％

[0029] The table above shows that the noise levels of Scheme 1 are 92 and 114 respectively, which is relatively high. The low-speed level of the roller just meets the industry standard, while the high-speed level does not meet the standard. The noise levels of Scheme 2 are 78 and 83 respectively. It can be seen that after using the internal and external noise reduction components, the noise is significantly reduced, and can be basically controlled to about 80 decibels, which is better than the industry standard. After adopting the optimized scheme of this invention, the noise of Scheme 3 is further reduced compared to Scheme 2, to 58 and 67 respectively. This noise level is already at an advanced level. It can be concluded that the scheme with the curved inner wall of the tube 53 of the internal noise reduction component has a better noise reduction effect than the planar scheme. At a high speed of 100, the noise is only 67. At the 60 speed level, the increase is only 15.5% (i.e., (67-58) / 58). It can be seen that Scheme 3 not only has very low noise, but the 15.5% increase in high-speed noise is also better than the 23.9% level of the prior art. It can be seen that it has very good practicality and is more suitable for noise control of high-speed belt conveyors.

[0030] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0031] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A noise-reducing idler roller for a belt conveyor, comprising a roller body, a roller shaft, a bearing, and a bearing housing, wherein the bearing housing is installed at both ends inside the roller body, the bearing is installed within the bearing housing, and the roller shaft is installed within the bearing and passes through the roller body, characterized in that... Also includes: The system includes an inner noise reduction component and an outer noise reduction component. The inner noise reduction component is disposed between the inner wall of the bearing housing and the bearing, and is used to reduce noise between the bearing housing and the bearing. The inner noise reduction component includes a noise reduction ring disposed between the inner wall of the bearing housing and the bearing. Several channels are spaced apart inside the noise reduction ring, and sound-absorbing elements are disposed in the channels. The outer noise reduction component is disposed on the outer wall of the roller body, and is used to reduce noise between the roller body and the conveyor belt. Several exhaust channels are provided on the side wall of the roller body. The outer noise reduction component includes several washers fixedly connected to the outer wall of the roller body. The several washers correspond one-to-one with the several exhaust channels and are connected. Several airbags are fixedly disposed on the inner wall of the roller body. The several airbags correspond one-to-one with the several exhaust channels and are connected. An elastic element is also provided inside the roller body. The elastic element is located on both sides of the airbag. One end of the elastic element is fixed in position, and the other end is in elastic contact with the airbag.

2. The noise-reducing idler roller for a belt conveyor according to claim 1, characterized in that: The washer opening has a notch.

3. The noise-reducing idler roller for a belt conveyor according to claim 2, characterized in that: The noise reduction coil is made of a deformable material.

4. A noise-reducing idler roller for a belt conveyor according to claim 3, characterized in that: The sound-absorbing component includes a hollow tube body, the outer wall of the tube body matching the inner wall of the channel, the inner wall of the tube body being curved, and a sound-absorbing material being placed inside the tube body.

5. A noise-reducing idler roller for a belt conveyor according to claim 4, characterized in that: The sound-absorbing material is a honeycomb-shaped flexible material.

6. A noise-reducing idler roller for a belt conveyor according to claim 5, characterized in that: It also includes a buffer assembly, which includes a support frame, an outer sleeve, an outer rod, and rollers. The support frame includes a first connecting rod and a second connecting rod. One end of the first connecting rod is fixedly connected to the inner wall of the roller body, and the other end is connected to an annular component. The annular component is arranged around the outside of the roller shaft, and a gap is reserved between the roller shafts to avoid friction. The second connecting rod connects the two first connecting rods. Several outer sleeves are fixedly set on the support frame. One end of the outer sleeve is sealed and the other end is open. One end of the outer rod is inserted into the inside of the outer sleeve, and the other end is connected to the roller. The roller makes rolling contact with the roller shaft. Space is reserved inside the outer sleeve for the outer rod to move.

7. A noise-reducing idler roller for a belt conveyor according to claim 6, characterized in that: An inner sleeve, an inner sleeve rod, and a sealing head are also provided inside the outer sleeve. The sealing section of the inner sleeve is fixedly connected to the inside of the outer sleeve. One end of the inner sleeve rod is inserted into the inside of the inner sleeve, and the other end is fixedly connected to the outer sleeve rod. A space is reserved inside the inner sleeve. The sealing head is set at the end of the inner sleeve rod, and the sealing head seals the space inside the inner sleeve, filling the space with air.

8. A noise-reducing idler roller for a belt conveyor according to claim 7, characterized in that: The buffer assembly also includes an inner spring.

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