Horizontally pivoting edge single chain flight conveyor spaced tooth wear resistant sprocket and method of manufacture

Abstract

A manufacturing method of a horizontal rotary edge single chain scraper conveyor interval tooth wear-resistant sprocket, comprising the following steps: designing and calculating various important parameters of the sprocket; machining the sprocket body according to the obtained various important parameters of the sprocket; machining the movable lining plate; assembling and fixing the machined sprocket body and the movable lining plate through bolts; and finishing and heat treating the assembled sprocket assembly. The interval tooth wear-resistant sprocket manufactured by the method has a pitch at the sprocket chain nest which is 3 times the pitch of the round link chain, the interval tooth sprocket can be matched with the conventional round link chain, a variable pitch chain does not need to be designed separately, and the universality of the interval tooth sprocket is improved; the sprocket can provide a larger space to avoid interference with the guide scraper; the upper and lower tooth chain nests of the interval tooth sprocket and the upper surface of the lower tooth are subjected to local induction quenching treatment, and the movable lining plate is arranged on the upper surface of the lower tooth to enhance the wear resistance. The application also provides a horizontal rotary edge single chain scraper conveyor interval tooth wear-resistant sprocket.

Description

Technical Field

[0001] This invention relates to the field of spaced toothed sprocket technology, and more particularly to a wear-resistant spaced toothed sprocket for a horizontally rotating side single-chain scraper conveyor and its manufacturing method. Background Technology

[0002] In recent years, with the development of underground mining technology in non-coal mines, the application of long-arm mechanized underground mining technology to hard rock ore working faces in non-coal mines such as bauxite, phosphate, and manganese mines has increasingly become a future technological development trend. These non-coal mines typically have poor geological conditions, large variations in ore body thickness, and many thin ore layers. Traditional scraper conveyors, with their high height requirements and limitations in matching with mining machines, cannot adequately meet the needs of thin ore layer working faces in non-coal mines. Therefore, the research, development, and application of a special type of machine—the side-chain scraper conveyor—has been undertaken. Because the side-chain scraper conveyor has only one chain, located on one side of the scraper end, the scraper itself has a cantilever beam structure. During material conveying, the scraper deflects under the tension of the chain and the thrust of the material. To prevent this deflection, a guide structure is added to the scraper end. When the scraper passes over the sprocket, the guide structure, being too large, collides and interferes with the sprocket teeth. Figure 2 As shown. Summary of the Invention

[0003] In order to solve the technical problems existing in the above-mentioned technology, it is necessary to provide a method for manufacturing a wear-resistant sprocket with spaced teeth for a horizontally rotating single-chain scraper conveyor.

[0004] A method for manufacturing a wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor includes the following steps:

[0005] Step 1: Perform design calculations for all important parameters of the sprocket;

[0006] Step 2: Based on the obtained key parameters of the sprocket, process the sprocket body;

[0007] Step 3: Process the movable liner;

[0008] Step 4: Assemble and fix the machined sprocket body and the movable liner plate with bolts;

[0009] Step 5: Perform precision machining and heat treatment on the assembled sprocket assembly.

[0010] Preferably, in step 2, the sprocket body is processed in the following manner:

[0011] ① The steel billet is forged into two semi-ring blank models;

[0012] ②The mating surfaces of the two semi-ring blanks are machined using a milling machine, and a welding bevel is machined on the mating surfaces;

[0013] ③ Assemble and position the upper and lower half-ring sprockets, and weld them together;

[0014] ④ Rough machining is performed on the welded sprocket, including large dimensions such as the inner hole and outer circle;

[0015] ⑤ Perform heat treatment on the sprocket to eliminate welding thermal stress and improve the overall mechanical performance of the sprocket;

[0016] ⑥ Milling machine finishes the mating surface between the lower sprocket and the live liner; flatness 0.05mm, roughness Ra3.2;

[0017] ⑦ Drill the mounting hole for the liner plate on the lower sprocket teeth and tap the internal thread.

[0018] Preferably, when quenching and tempering the sprocket, the quenching temperature is 900℃, the low-temperature tempering temperature is 180~200℃, and the time is 2.5h.

[0019] Preferably, in step 3, the movable liner is processed in the following manner:

[0020] ① Cut the high-strength wear-resistant plate into rough blanks according to the shape of the live liner (leaving machining allowance), and select wear-resistant plate with a thickness greater than the thickness of the finished live liner part;

[0021] ② The blank of the live liner plate is normalized and then air-cooled;

[0022] ③ The mating surface between the live liner and the sprocket is finished by milling, with a flatness of 0.05mm and a roughness of Ra3.2;

[0023] ④ Drill stepped holes for mounting bolts on the live liner.

[0024] Preferably, when normalizing the blank of the live lining plate, the normalizing temperature is 950-980℃ and the holding time is 1-3 hours.

[0025] Preferably, in step 5, when performing finishing and heat treatment on the sprocket assembly, the following method is adopted:

[0026] ①Precision boring of the sprocket inner hole;

[0027] ② Milling the internal keyway;

[0028] ③ Milling machine precision chain grooves and tooth profiles;

[0029] ④ The contact surfaces of the chain socket and the live liner with the round link chain are carburized and quenched. After heat treatment, the hardness of the material at a depth of 20mm in the quenched layer is not less than HRC55.

[0030] Preferably, the following method is used for carburizing and quenching treatment of the contact surfaces between the chain socket and the live liner and the circular link chain.

[0031] a. Clean the sprocket with a metal cleaner to remove surface oil and dirt;

[0032] b. Apply a waterproof coating to areas other than the chain groove and live liner;

[0033] c. Carburize and quench the sprocket;

[0034] d. Perform cold treatment on the sprocket at a temperature of -50℃ for 1.5 hours;

[0035] e. Temper the sprocket at a temperature of 180–200°C for 6 hours.

[0036] Preferably, in step 1, the following method is used when performing design calculations on the various important parameters of the sprocket:

[0037] S1: Based on the meshing principle of sprockets and circular chains, establish a diagram showing the meshing relationship between spaced toothed sprockets and circular chains;

[0038] S2: Based on the established relationship diagram, the following important parameters of the spaced tooth sprocket are determined: the angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the gear tooth and the center of the sprocket and the symmetrical center line of the chain socket. Circular link chain pitch Circular chain diameter pitch circle diameter of the interleaved sprocket The distance from the center of the sprocket to the bottom plane of the sprocket socket Chain nest length tooth root radius ;

[0039] S3: Establish the pitch circle diameter of the intermittent sprocket. Circular link chain pitch Circular link chain diameter The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. The logical relationship formula between them, namely

[0040] (1);

[0041] S4: Establish sprocket pitch angle The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. Number of sprocket teeth The logical relationship formula between them, namely

[0042] (2);

[0043] S5: Establish sprocket pitch angle The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. The logical relationship formula between them, namely

[0044] (3);

[0045] S6: Based on the established logical relationship formulas (1), (2), and (3), the sprocket pitch circle diameter is derived. The logical relationship formula (4);

[0046] S7: Based on the meshing relationship diagram of the spaced toothed sprocket and the circular link chain, establish the geometric relationship diagram of the vertical ring groove diameter, and obtain the vertical ring groove diameter through the geometric relationship diagram. The logical relationship formula (5);

[0047] S8: The diameter of the sprocket vertical ring groove is derived by using logical relationship formulas (2) and (5). The logical relationship formula (6);

[0048] S9: Based on the meshing relationship diagram of the interlocking sprocket and the circular chain, establish a geometric relationship diagram of the distance from the sprocket center to the bottom plane of the sprocket housing, and obtain the distance from the sprocket center to the bottom plane of the sprocket housing through the geometric relationship diagram of the distance from the sprocket center to the bottom plane of the sprocket housing. The logical relationship formula (7);

[0049] S10: The distance from the center of the chain socket to the bottom surface of the chain socket is derived by using logical relationship formulas (2) and (7). The final logical relationship formula (8);

[0050] S11: Considering that the actual pitch of the circular link chain is greater than the theoretical value due to the stretching of the chain and the manufacturing error of the chain, a diagram of the actual meshing relationship between the spaced toothed sprocket and the circular link chain is established, and the actual pitch of the spaced toothed sprocket is determined by the diagram of the actual meshing relationship between the spaced toothed sprocket and the circular link chain.

[0051] S12: Considering the deformation length of the circular link chain and the cumulative manufacturing error, determine the sprocket socket length of the spacer tooth sprocket. ;

[0052] S13: Determine the radius of the tooth root arc .

[0053] A wear-resistant sprocket with spaced teeth for a horizontally rotating single-chain scraper conveyor is manufactured using the aforementioned manufacturing method for a wear-resistant sprocket with spaced teeth for a horizontally rotating single-chain scraper conveyor.

[0054] Preferably, it includes a movable liner and a sprocket body; upper gear teeth and lower gear teeth are sequentially arranged along the axial direction of the sprocket body, the distance between the chain sockets of adjacent upper gear teeth and adjacent lower gear teeth is three times the pitch of the circular chain, a groove is left between the upper gear teeth and the lower gear teeth for the circular chain to be inserted, an internal spline is provided along the axis of the sprocket body, and the movable liner is detachably fixed to the upper surface of the lower gear teeth.

[0055] Compared with the prior art, the method for manufacturing a horizontally rotating, single-chain scraper conveyor with spaced tooth wear-resistant sprockets provided by the present invention has the following advantages:

[0056] (1) The pitch at the sprocket socket is 3 times that of the circular link chain. The socket meshes with the chain link group consisting of two flat links and one vertical link. This spaced tooth sprocket can be used with conventional circular link chains without the need for a separately designed variable pitch chain, thus improving the versatility of the spaced tooth sprocket.

[0057] (2) The guide scraper is fixed on the flat ring of the chain link assembly. Since the sprocket pitch at the chain link assembly is 3 times the pitch of the circular chain, the sprocket can provide a larger space to avoid interference with the guide scraper.

[0058] (3) When the circular chain passes around the spaced tooth sprocket, the upper and lower tooth sockets of the sprocket are the main wear surfaces. At the same time, due to the effect of gravity, the flat ring of the circular chain will come into contact with the upper surface of the lower tooth after the sprocket wears down for a period of time. Therefore, the upper and lower tooth sockets and the upper surface of the lower tooth of the spaced tooth sprocket are subjected to local induction hardening treatment, and a live liner is set on the upper surface of the lower tooth to enhance wear resistance.

[0059] (4) The contact length between the sprocket socket plane and the circular chain is twice that of the conventional sprocket socket plane and the circular chain. The increased contact area between the socket and the circular chain leads to a decrease in the pressure between the socket and the circular chain, and the wear resistance of the socket is greatly improved. Attached Figure Description

[0060] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0061] Figure 1 This is a diagram showing the conventional assembly of sprockets, chains, and scrapers in existing technologies.

[0062] Figure 2 This is a schematic diagram illustrating the interference between conventional sprockets, chains, and guide scrapers in existing technologies.

[0063] Figure 3 This is a diagram showing the meshing relationship between the spaced toothed sprocket and the circular chain.

[0064] Figure 4 This is a geometric diagram showing the diameter of the vertical ring groove.

[0065] Figure 5 This is a geometric diagram showing the distance from the center of the sprocket to the bottom plane of the sprocket housing.

[0066] Figure 6 This diagram shows the actual meshing relationship between the spaced toothed sprocket and the circular chain.

[0067] Figure 7 This is a schematic diagram showing the interaction between the toothed sprocket, chain, and scraper.

[0068] Figure 8 This is a schematic diagram of the spaced toothed sprocket of the present invention.

[0069] Figure 9 For the present invention Figure 8 A cross-sectional structural diagram.

[0070] Figure 10 This is a comparison chart of the contact length between the sprocket and the sprocket housing in a standard sprocket and the contact length between the sprocket housing and the sprocket in a toothed sprocket.

[0071] In the diagram: sprocket body 01, movable liner 02, upper gear tooth 03, lower gear tooth 04, groove 05, internal spline 06, guide scraper 07, circular link chain 08. Detailed Implementation

[0072] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0073] In the description of this invention, it should be understood that the terms "upper", "middle", "outer", "inner", "lower", etc., which indicate orientation or positional relationship, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the components or elements referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting this invention.

[0074] In one embodiment, the present invention provides a method for manufacturing a wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor, comprising the following steps:

[0075] Step 1: Perform design calculations for all important parameters of the sprocket;

[0076] Step 2: Based on the obtained key parameters of the sprocket, process the sprocket body; the specific processing method is as follows:

[0077] ① The steel billet is forged into two semi-ring blank models;

[0078] ②The mating surfaces of the two semi-ring blanks are machined using a milling machine, and a welding bevel is machined on the mating surfaces;

[0079] ③ Assemble and position the upper and lower half-ring sprockets, and weld them together;

[0080] ④ Rough machining is performed on the welded sprocket, including large dimensions such as the inner hole and outer circle;

[0081] ⑤ The sprocket is subjected to quenching and tempering treatment to eliminate welding thermal stress and improve the overall mechanical properties of the sprocket; the quenching temperature is 900℃, the low-temperature tempering temperature is 180~200℃, and the time is 2.5h;

[0082] ⑥ Milling machine finishes the mating surface between the lower sprocket and the live liner; flatness 0.05mm, roughness Ra3.2;

[0083] ⑦ Drill the mounting hole for the liner plate on the lower sprocket teeth and tap the internal thread.

[0084] Step 3: Process the movable liner; the specific processing method is as follows:

[0085] ① Cut the high-strength wear-resistant plate into rough blanks according to the shape of the live liner (leaving machining allowance), and select wear-resistant plate with a thickness greater than the thickness of the finished live liner part;

[0086] ② Normalize the blank of the live lining plate and then air cool it; normalize at 950-980℃ and hold for 1-3 hours.

[0087] ③ The mating surface between the live liner and the sprocket is finished by milling, with a flatness of 0.05mm and a roughness of Ra3.2;

[0088] ④ Drill stepped holes for mounting bolts on the live liner.

[0089] Step 4: Assemble and fix the machined sprocket body and the movable liner plate with bolts;

[0090] Step 5: Perform precision machining and heat treatment on the assembled sprocket assembly; the specific machining methods are as follows:

[0091] ① Precision boring of the sprocket inner hole;

[0092] ② Milling the internal keyway;

[0093] ③ Milling machine precision chain grooves and tooth profiles;

[0094] ④ The contact surfaces of the chain socket and the live liner with the round link chain are carburized and quenched. After heat treatment, the hardness of the material at a depth of 20mm in the quenched layer is not less than HRC55.

[0095] The following methods are used during carburizing and quenching.

[0096] a. Clean the sprocket with a metal cleaner to remove surface oil and dirt;

[0097] b. Apply a waterproof coating to areas other than the chain groove and live liner;

[0098] c. Carburize and quench the sprocket;

[0099] d. Perform cold treatment on the sprocket at a temperature of -50℃ for 1.5 hours;

[0100] e. Temper the sprocket at a temperature of 180–200°C for 6 hours.

[0101] Specifically, the following methods are used when designing and calculating the various important parameters of the sprocket.

[0102] S1: Based on the meshing principle of sprockets and circular chains, establish a diagram showing the meshing relationship between spaced toothed sprockets and circular chains;

[0103] S2: Based on the established relationship diagram, the following important parameters of the spaced tooth sprocket are determined: the angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. Circular link chain pitch Circular chain diameter pitch circle diameter of the interleaved sprocket The distance from the center of the sprocket to the bottom plane of the sprocket socket Chain nest length tooth root radius ;

[0104] S3: Establish the pitch circle diameter of the intermittent sprocket. Circular link chain pitch Circular link chain diameter The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. The logical relationship formula between them, namely

[0105] (1);

[0106] S4: Establish sprocket pitch angle The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. Number of sprocket teeth The logical relationship formula between them, namely

[0107] (2);

[0108] S5: Establish sprocket pitch angle The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. The logical relationship formula between them, namely

[0109] (3);

[0110] S6: Based on the established logical relationship formulas (1), (2), and (3), the sprocket pitch circle diameter is derived. The logical relationship formula (4);

[0111] S7: Based on the meshing relationship diagram of the spaced toothed sprocket and the circular link chain, establish the geometric relationship diagram of the vertical ring groove diameter, and obtain the vertical ring groove diameter through the geometric relationship diagram. The logical relationship formula (5);

[0112] S8: The diameter of the sprocket vertical ring groove is derived by using logical relationship formulas (2) and (5). The logical relationship formula (6);

[0113] S9: Based on the meshing relationship diagram of the interlocking sprocket and the circular chain, establish a geometric relationship diagram of the distance from the sprocket center to the bottom plane of the sprocket housing, and obtain the distance from the sprocket center to the bottom plane of the sprocket housing through the geometric relationship diagram of the distance from the sprocket center to the bottom plane of the sprocket housing. The logical relationship formula (7);

[0114] S10: The distance from the center of the chain socket to the bottom surface of the chain socket is derived by using logical relationship formulas (2) and (7). The final logical relationship formula (8);

[0115] S11: Considering that the actual pitch of the circular link chain is greater than the theoretical value due to the stretching of the chain and the manufacturing error of the chain, a diagram of the actual meshing relationship between the spaced toothed sprocket and the circular link chain is established, and the actual pitch of the spaced toothed sprocket is determined by the diagram of the actual meshing relationship between the spaced toothed sprocket and the circular link chain.

[0116] S12: Considering the deformation length of the circular link chain and the cumulative manufacturing error, determine the sprocket socket length of the spacer tooth sprocket. ;

[0117] S13: Determine the radius of the tooth root arc .

[0118] In step S6, the logical relation formula (4) is specifically expressed as follows:

[0119] (4);

[0120] In the formula: The pitch of the circular chain; The pitch circle diameter of the toothed sprocket; This represents the number of teeth on the sprocket.

[0121] In step S7, the logical relation formula (5) is specifically expressed as follows:

[0122] (5);

[0123] In the formula: The diameter of the sprocket vertical ring groove; This is the maximum outer width of the circular chain; Select according to Table A.1 in GB / T 24503 standard; The pitch of the circular chain; The diameter of the circular chain; It is the sprocket pitch angle.

[0124] In step S8, the logical relation formula (6) is specifically represented as follows:

[0125] (6);

[0126] In the formula: The diameter of the sprocket vertical ring groove; The pitch of the circular chain; This is the maximum outer width of the circular chain; Select according to Table A.1 in GB / T24503 standard; The pitch of the circular chain; This represents the number of teeth on the sprocket.

[0127] In step S9, the logical relation formula (7) is specifically represented as follows:

[0128] (7);

[0129] In the formula: This is the distance from the center of the sprocket to the bottom plane of the sprocket housing; The pitch of the circular chain; The diameter of the circular chain; It is the sprocket pitch angle.

[0130] In step S10, the logical relation formula (8) is specifically expressed as follows:

[0131] (8);

[0132] In the formula: This is the distance from the center of the sprocket to the bottom plane of the sprocket housing; The diameter of the circular chain; This represents the number of teeth on the sprocket.

[0133] In step S11, the actual pitch of the toothed sprocket is obtained in the following way.

[0134] When a standard circular chain meshes with a spaced toothed sprocket at its nominal diameter, the pitch of the spaced toothed sprocket is... It is equal to 4 times the pitch of the circular chain, that is, the pitch of the spaced toothed sprocket is:

[0135] ;

[0136] Due to chain stretching and manufacturing errors, the actual pitch of a circular link chain is greater than the theoretical value, corresponding to the actual pitch of the sprocket teeth. ;

[0137] set up (9); and (10);

[0138] Based on the actual meshing relationship diagram of the toothed sprocket and the circular link chain, the following is derived:

[0139] (11);

[0140] Based on the derivation of formulas (10) and (11),

[0141] (12);

[0142] Based on formulas (9) and (12), the actual pitch of the toothed sprocket is derived as follows:

[0143] (13);

[0144] In the formula: and This refers to the theoretical pitch of the sprocket. The pitch of the circular chain; The diameter of the circular chain; This represents the number of sprocket teeth. and The sprocket pitch is adjusted to account for the stretching of the circular link chain and manufacturing errors. This is the sum of tensile deformation and manufacturing error of the combined chain links; It is the difference between the actual size of the circular chain at the sprocket teeth after deformation and the theoretical size before deformation.

[0145] In step S12, the chain socket length of the spaced toothed sprocket is... Obtained through the following methods, namely

[0146] (14);

[0147] Considering the larger deformation length and cumulative manufacturing error of the links in a circular chain, Increase it appropriately based on the suggested value, that is At this time, the corresponding sprocket socket length is:

[0148] (14);

[0149] In the formula: The pitch of the circular chain; The diameter of the circular chain; The actual chain performance and operating conditions are related to the chain's inherent performance, including manufacturing errors and cross-sectional dimensions. The value is inversely proportional to the chain's elastic modulus (and) The value is inversely proportional); the operating condition is the tension on the chain (and) (The value is directly proportional).

[0150] In step S13, the radius of the tooth root arc It is obtained through the following formula, i.e.

[0151] (15);

[0152] In the formula: The pitch of the circular chain; The diameter of the circular chain.

[0153] Please refer to Figures 7 to 9 In one embodiment, the present invention provides a horizontally rotating side single-chain scraper conveyor spacer tooth wear-resistant sprocket, which is manufactured using a method for manufacturing horizontally rotating side single-chain scraper conveyor spacer tooth wear-resistant sprockets.

[0154] Specifically, the spaced-tooth wear-resistant sprocket includes a movable liner 02 and a sprocket body 01. Upper gear teeth 03 and lower gear teeth 04 are sequentially arranged along the axial direction of the sprocket body 01. The distance between the chain sockets of adjacent upper gear teeth 03 and adjacent lower gear teeth 04 is three times the pitch of the circular link chain 07. A groove 05 is provided between the upper gear teeth 03 and the lower gear teeth 04 for the circular link chain 07 to be inserted. An internal spline 06 is provided along the axis of the sprocket body. The movable liner 02 is detachably fixed to the upper surface of the lower gear teeth 04; it can be fixed by bolts.

[0155] To ensure that the flat ring of the circular chain can still effectively enter the gap between the upper and lower gear teeth after the sprocket has worn down after running for a period of time, the chamfer size of the upper gear teeth is 8×15mm, and the chamfer size of the lower gear teeth is 15×20mm.

[0156] After running for a period of time, as the sprocket wears down, the meshing point between the circular chain and the sprocket moves down, and the proportion of force borne by the lower sprocket tooth increases. Therefore, the spaced tooth sprocket has an asymmetrical structure, with the lower tooth being 20% ​​thicker than the upper tooth.

[0157] Please refer to Figure 10 Figure a shows the contact length between the chain socket and the sprocket in a conventional sprocket, and Figure b shows the contact length between the chain socket and the sprocket in a toothed sprocket. As can be seen from the figures, the contact length between the chain socket plane and the circular chain in a toothed sprocket is twice that of the conventional sprocket. The increased contact area between the chain socket and the circular chain leads to a decrease in the pressure between them, which greatly improves the wear resistance of the chain socket.

[0158] The above-disclosed embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the invention. Those skilled in the art will understand that implementing all or part of the above-described embodiments and making equivalent changes in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A method for manufacturing a wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor, characterized in that: Includes the following steps, Step 1: Perform design calculations for all important parameters of the sprocket; Step 2: Based on the obtained key parameters of the sprocket, process the sprocket body; Step 3: Process the movable liner; Step 4: Assemble and fix the machined sprocket body and the movable liner plate with bolts; Step 5: Perform precision machining and heat treatment on the assembled sprocket assembly; In step 1, the following method is used to perform design calculations on the various important parameters of the sprocket. S1: Based on the meshing principle of sprockets and circular chains, establish a diagram showing the meshing relationship between spaced toothed sprockets and circular chains; S2: Based on the established relationship diagram, the following important parameters of the spaced tooth sprocket are determined: the angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the gear tooth and the center of the sprocket and the symmetrical center line of the chain socket. Circular link chain pitch Circular chain diameter pitch circle diameter of the interleaved sprocket The distance from the center of the sprocket to the bottom plane of the sprocket socket Chain nest length tooth root radius ; S3: Establish the pitch circle diameter of the intermittent sprocket. Circular link chain pitch Circular link chain diameter The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. The logical relationship formula between them, namely （1）； S4: Establish sprocket pitch angle The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. Number of sprocket teeth The logical relationship formula between them, namely （2）； S5: Establish sprocket pitch angle The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the center line of symmetry of the tooth. The angle between the line connecting the center of the vertical ring section closest to the tooth and the center of the sprocket and the symmetrical center line of the chain socket. The logical relationship formula between them, namely （3）； S6: Based on the established logical relationship formulas (1), (2), and (3), the sprocket pitch circle diameter is derived. The logical relationship formula (4); S7: Based on the meshing relationship diagram of the spaced toothed sprocket and the circular link chain, establish the geometric relationship diagram of the vertical ring groove diameter, and obtain the vertical ring groove diameter through the geometric relationship diagram. The logical relationship formula (5); S8: The diameter of the sprocket vertical ring groove is derived by using logical relationship formulas (2) and (5). The logical relationship formula (6); S9: Based on the meshing relationship diagram of the interlocking sprocket and the circular chain, establish a geometric relationship diagram of the distance from the sprocket center to the bottom plane of the sprocket housing, and obtain the distance from the sprocket center to the bottom plane of the sprocket housing through the geometric relationship diagram of the distance from the sprocket center to the bottom plane of the sprocket housing. The logical relationship formula (7); S10: The distance from the center of the chain socket to the bottom surface of the chain socket is derived by using logical relationship formulas (2) and (7). The final logical relationship formula (8); S11: Considering that the actual pitch of the circular link chain is greater than the theoretical value due to the stretching of the chain and the manufacturing error of the chain, a diagram of the actual meshing relationship between the spaced toothed sprocket and the circular link chain is established, and the actual pitch of the spaced toothed sprocket is determined by the diagram of the actual meshing relationship between the spaced toothed sprocket and the circular link chain. S12: Considering the deformation length of the circular link chain and the cumulative manufacturing error, determine the chain socket length of the spacer tooth sprocket. ; S13: Determine the radius of the tooth root arc .

2. The method for manufacturing a wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor according to claim 1, characterized in that: In step 2, the sprocket body is machined using the following method. ① The steel billet is forged into two semi-ring blank models; ②The mating surfaces of the two semi-ring blanks are machined using a milling machine, and a welding bevel is machined on the mating surfaces; ③ Assemble and position the upper and lower half-ring sprockets, and weld them together; ④ Perform rough machining on the welded sprocket; ⑤ Perform heat treatment on the sprocket to eliminate welding thermal stress and improve the overall mechanical performance of the sprocket; ⑥ Milling machine finishes the mating surface between the lower sprocket and the live liner; flatness 0.05mm, roughness Ra3.2; ⑦ Drill the mounting hole for the liner plate on the lower sprocket teeth and tap the internal thread.

3. The method for manufacturing a wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor according to claim 2, characterized in that: When quenching and tempering the sprocket, the quenching temperature is 900℃, the low-temperature tempering temperature is 180~200℃, and the time is 2.5h.

4. The method for manufacturing a wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor according to claim 1, characterized in that: In step 3, the movable liner is processed in the following manner. ① Cut the high-strength wear-resistant plate into rough blanks according to the shape of the live liner, and select a wear-resistant plate with a thickness greater than the thickness of the finished part of the live liner. ② The blank of the live liner plate is normalized and then air-cooled; ③ The mating surface between the live liner and the sprocket is finished by milling, with a flatness of 0.05mm and a roughness of Ra3.2; ④ Drill stepped holes for mounting bolts on the live liner.

5. The method for manufacturing a wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor according to claim 4, characterized in that: When normalizing the blank of the live lining plate, the normalizing temperature is 950-980℃ and the holding time is 1-3 hours.

6. The method for manufacturing a wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor according to claim 1, characterized in that: In step 5, the sprocket assembly undergoes finishing and heat treatment in the following manner. ① Precision boring of the sprocket inner hole; ② Milling the internal keyway; ③ Milling machine precision chain grooves and tooth profiles; ④ The contact surfaces of the chain socket and the live liner with the round link chain are carburized and quenched. After heat treatment, the hardness of the material at a depth of 20mm in the quenched layer is not less than HRC55.

7. The method for manufacturing a wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor according to claim 6, characterized in that: The following method is used for carburizing and quenching treatment of the contact surfaces between the chain socket and the live liner and the circular link chain. a. Clean the sprocket with a metal cleaner to remove surface oil and dirt; b. Apply a waterproof coating to areas other than the chain groove and live liner; c. Carburize and quench the sprocket; d. Perform cold treatment on the sprocket at a temperature of -50℃ for 1.5 hours; e. Temper the sprocket at a temperature of 180–200°C for 6 hours.

8. A wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor, characterized in that: It is manufactured using the manufacturing method of the horizontally rotating side single-chain scraper conveyor spaced tooth wear-resistant sprocket as described in any one of claims 1-7.

9. The wear-resistant, spaced-tooth sprocket for a horizontally rotating single-chain scraper conveyor according to claim 8, characterized in that: It includes a movable liner and a sprocket body; upper and lower teeth are arranged sequentially along the axial direction of the sprocket body, the distance between the chain sockets of adjacent upper and lower teeth is three times the pitch of the circular chain, a groove is left between the upper and lower teeth for the circular chain to be inserted, an internal spline is provided along the axis of the sprocket body, and the movable liner is detachably fixed to the upper surface of the lower teeth.

Images