A kind of wear-resistant ceramic rubber ring for belt conveyor carrier roller and preparation method

Abstract

The application discloses an anti-erosion ceramic rubber ring for a belt conveyor carrier roller and a preparation method thereof. In order to ensure better bonding effect of the rubber and the ceramic sheet and prevent the ceramic sheet from falling off under repeated elastic deformation of the rubber ring, the ceramic sheet is thickened to a thickness of not less than 7 mm, and the thickness of the rubber wrapped thereon is not less than 6 mm. A large roughness is formed on the outer surface of the ceramic sheet, the ceramic sheet is wrapped by the rubber from five surfaces, the contact area of the rubber and the ceramic sheet is increased as much as possible, and an adhesive is applied on the ceramic sheet to ensure the bonding performance of the rubber and the ceramic. An elastic deformation amount buffer structure is arranged on the inner and outer rings, and a certain deformation amount is absorbed by the buffer groove when the rubber ring is elastically deformed under stress, so that the deformation amount of the bonding position of the rubber and the ceramic sheet is reduced. In addition, the buffer holes are uniformly distributed with the center of the mounting hole as the center, so that the deformation amount can be absorbed and the total amount of the rubber ring can be reduced.

Description

Technical Field

[0001] This invention relates to the field of rubber ring technology, and in particular to a wear-resistant ceramic rubber ring for belt conveyor idlers and its preparation method. Background Technology

[0002] Existing belt conveyors (such as TD75, DTII, and DTII(A) type belt conveyors) use buffer idlers or comb-shaped idlers. The idler steel tube is mounted on the idler shaft via bearings, and a rubber ring is fitted onto the idler tube, secured by a steel retaining ring. To facilitate fitting with the idler tube, the rubber ring's bore diameter is 0.5mm larger than the idler tube's outer diameter. Thus, when material falls onto the conveyor belt, the force is transmitted to the rubber ring, causing it to continuously move radially. The clearance of this movement is exactly 0.5mm within the inner bore of the rubber ring. This continuous radial friction results in the rubber ring's inner diameter being 0.5mm smaller than the idler steel tube's outer diameter, shortening its service life. Thirdly, the original rubber ring hardness is generally Shore (A) 65±3, which hardens in winter and can cause it to crack.

[0003] However, existing idler rollers have the following problems: 1. Materials with high surface hardness, when transported by belt conveyors, will adhere to the surface of the conveyor belt if unloading and cleaning are not done properly or if the material spills. This will cause high abrasiveness to components in contact with the conveyor belt, such as idlers (e.g., coke, semi-coke, petroleum coke). In particular, the lower idlers (comb idlers, etc.) that are in direct contact with the conveyor belt bearing surface often suffer severe surface wear and fail, resulting in high equipment maintenance costs.

[0004] II. For highly abrasive materials, traditional belt conveyors often employ the following methods to mitigate wear: 1. Thicken the steel pipe of the roller body to extend the wear and tear time. This method can appropriately extend the wear time, but it increases the initial investment cost. In addition, due to the increased rotational weight of the roller, the overall operating power will increase, and the later maintenance cost will also rise.

[0005] 2. Use of ceramic rollers. The roller body is made directly from ceramic tubes. The high hardness of the ceramic surface can greatly alleviate the abrasion problem. However, due to the low forming rate, poor forming accuracy, and poor machinability of ceramic tubes, the radial runout, rotational resistance, axial load-bearing capacity, dust and water resistance, and other performance characteristics of all-ceramic rollers are not satisfactory, and the equipment cannot operate stably for a long time. In addition, the thickness of the ceramic tube needs to be relatively thick, which increases the rotational weight of the entire roller and the operating power of the entire set of equipment. The fragility of ceramics means that, in actual use, due to factors such as transportation, on-site conditions, and the working habits of maintenance personnel, the failure rate of ceramic rollers due to breakage increases significantly.

[0006] 3. Using spiral rollers. These rollers consist of ordinary steel rollers with spiral metal strips wound and fixed on their surface. While they provide some cleaning as the rollers rotate during operation, they can cause the conveyor belt to jump, leading to instability in the overall conveyor belt operation. Therefore, spiral rollers are often placed in the return section, starting from the head and moving towards the tail, with 3-5 sets configured. Furthermore, once the spiral metal strips wear down, they revert to ordinary steel rollers, resulting in poor wear resistance.

[0007] 4. Install a belt turning device. This device can turn the bearing surface of the conveyor belt in the return bearing section, allowing the lower idler roller to contact the non-bearing surface of the conveyor belt, reducing roller wear. However, the installation of the belt turning device not only increases the equipment investment cost, but also requires a certain amount of space and length, so it is more suitable for long-distance belt conveyors and is generally not installed on ordinary belt conveyors that are a few hundred meters long.

[0008] 5. Configure comb-shaped idlers. Comb-shaped idlers consist of steel rollers with spaced rubber rings arranged around them on the return section. This reduces the contact area between the roller and the conveyor belt's bearing surface, decreasing roller wear and allowing material adhering to the conveyor belt to fall off as it passes over the rollers, resulting in smoother equipment operation. Manufacturing is convenient, and compared to other wear-resistant roller configurations, roller performance is easier to guarantee, without significantly increasing equipment operating resistance or investment costs. However, the wear resistance of the rubber directly determines the lifespan of the comb-shaped idlers. Summary of the Invention

[0009] To address the aforementioned technical problems, this invention provides a wear-resistant ceramic rubber ring for belt conveyor idlers and its preparation method.

[0010] To achieve the above objectives, the present invention is implemented according to the following technical solution: One objective of this invention is to provide a wear-resistant ceramic rubber ring for belt conveyor idlers, comprising a rubber ring with a central mounting hole; the outer ring surface of the rubber ring is evenly distributed with a plurality of radially distributed first U-shaped buffer grooves, and toothed blocks are formed between adjacent first U-shaped buffer grooves; the two ends of the first U-shaped buffer grooves penetrate the axial end faces of the rubber ring; a ceramic sheet is fixed to the front end face of each toothed block; the inner ring surface of the rubber ring is evenly distributed with a plurality of radially distributed second U-shaped buffer grooves, and the two ends of the second U-shaped buffer grooves penetrate the axial end faces of the rubber ring.

[0011] Furthermore, each of the toothed blocks has a mounting groove on its front end face, and the ceramic sheet is fixed in the mounting groove, with the upper end face of the ceramic sheet located above the front end face of the toothed block.

[0012] Preferably, the thickness of the ceramic sheet is not less than 7 mm, and the depth of the mounting groove is not less than 6 mm.

[0013] Furthermore, the rubber ring on the outer ring of the mounting hole is evenly distributed with several buffer holes.

[0014] Furthermore, the number of the second U-shaped buffer grooves is half the number of the first U-shaped buffer grooves, and each second U-shaped buffer groove corresponds to one first U-shaped buffer groove. The center lines of the corresponding second U-shaped buffer groove and the first U-shaped buffer groove are on the same straight line, and a buffer hole is symmetrically opened on both sides of each second U-shaped buffer groove.

[0015] The second objective of this invention is to provide a method for preparing a wear-resistant ceramic rubber ring for belt conveyor idlers, comprising the following steps: S1. Assemble the mold onto the hot press molding machine. The mold consists of an upper template, a middle template, a lower template, a large core, a small core, and positioning pins. The center of the upper end face of the lower template has a circular groove corresponding to the mounting hole of the rubber ring. The outer periphery of the circular groove has a first annular groove, and the outer ring of the circular groove has a first annular stepped surface. The large core is installed in the circular groove. The large core includes a hollow cylinder with an outer diameter the same as the inner diameter of the mounting hole of the rubber ring. Several axially arranged cylinders are evenly distributed on the outer periphery of the hollow cylinder, and the cylinders are used to form the second U-shaped buffer groove of the rubber ring. The center of the middle template has a first through hole with the same outer diameter as the rubber ring. Several axially arranged U-shaped blocks are evenly distributed on the inner wall of the middle template. The U-shaped blocks are used to form the first U-shaped buffer groove of the rubber ring. The center of the inner wall of the middle template between two adjacent U-shaped blocks has an axial groove for installing ceramic pieces. The lower end face of the middle template has a groove that mates with the first annular groove. The first annular protrusion, the upper end face of the middle template has a second annular protrusion symmetrical to the first annular protrusion, the inner circle of the second annular protrusion has a second annular stepped surface; the center of the lower end face of the upper template has a column that matches the hollow cylinder, the lower end face of the column is used to contact the upper end face of the circular groove, the lower end face of the upper template around the column has a second annular groove that matches the second annular protrusion, the inner circle of the second annular groove has a third annular protrusion that matches the second annular stepped surface, the upper template of the inner circle of the third annular protrusion has several second through holes evenly distributed, the second through holes are fitted with small cores, the small cores are cylindrical, the ends of the small cores are used to extend to the upper end face of the lower template to form buffer holes for the rubber ring; the lower template, the middle template and the upper template have positioning pin holes at one end, the positioning pins are fitted in the positioning pin holes; first, the lower template is assembled on the hot press forming machine, then the middle template and the large core are installed in sequence, and then the mold is preheated. S2. Place the middle template in place, forming a mold cavity between the outer periphery of the large core and the inner ring of the middle template. Weigh the mixed rubber material and place it into the mold cavity. At the same time, place the ceramic sheet with adhesive applied into the groove of the middle template and fix it with rubber material. Finally, assemble the template and install the small core in the second through hole. Use positioning pins to position the upper template, middle template, and lower template for molding. The molding parameters are: temperature: 140℃~170℃, pressure: molding pressure 19MPa, exhaust pressure 19.5MPa, molding time: not less than 240 seconds. S3. Demold and grind off the rough edges to obtain the wear-resistant ceramic rubber ring for belt conveyor rollers.

[0016] Compared with existing technologies, this invention ensures a superior bonding effect between the rubber and ceramic sheet, preventing the ceramic sheet from detaching under repeated elastic deformation of the rubber ring. The ceramic sheet is thickened to at least 7mm, with a rubber coating of at least 6mm, resulting in a high surface roughness. The rubber wraps around all five sides of the ceramic sheet, maximizing the contact area between the rubber and ceramic. Adhesive is applied to the ceramic sheet to ensure strong adhesion. An elastic deformation buffer structure is incorporated into the inner and outer rings. When the rubber ring undergoes elastic deformation under stress, the buffer groove absorbs a certain amount of deformation, reducing deformation at the rubber-ceramic bond. Furthermore, buffer holes are designed, evenly distributed around the center of the mounting hole, which absorbs deformation and reduces the overall weight of the rubber ring. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the wear-resistant ceramic rubber ring for belt conveyor idlers of the present invention.

[0018] Figure 2 An exploded view of a mold used to manufacture wear-resistant ceramic rubber rings for belt conveyor idlers.

[0019] Figure 3 This is a schematic diagram of the lower mold plate of a mold used to prepare wear-resistant ceramic rubber rings for belt conveyor idlers.

[0020] Figure 4 This is a schematic diagram of the structure of a large core for a mold used to manufacture wear-resistant ceramic rubber rings for belt conveyor idlers.

[0021] Figure 5 This is a schematic diagram of the middle template of a mold used to prepare wear-resistant ceramic rubber rings for belt conveyor idlers.

[0022] Figure 6 This is a schematic diagram of the upper template of a mold used to prepare wear-resistant ceramic rubber rings for belt conveyor idlers.

[0023] Figure 7An isometric view of the upper template of a mold used to manufacture wear-resistant ceramic rubber rings for belt conveyor idlers. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. The specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention.

[0025] like Figure 1 As shown in the illustration, this embodiment exemplarily demonstrates a wear-resistant ceramic rubber ring for a belt conveyor idler roller, comprising a rubber ring 1 with a mounting hole 2 at its center; the outer ring surface of the rubber ring 1 is evenly distributed with a plurality of radially distributed first U-shaped buffer grooves 3, and toothed blocks 4 are formed between adjacent first U-shaped buffer grooves 3; the two ends of the first U-shaped buffer grooves 3 penetrate the axial end faces of the rubber ring 1; a ceramic sheet 5 is fixed to the front end face of each toothed block 4; the inner ring surface of the rubber ring 1 is evenly distributed with a plurality of radially distributed second U-shaped buffer grooves 6, and the two ends of the second U-shaped buffer grooves 6 penetrate the axial end faces of the rubber ring 1. The inner and outer rings of the rubber ring 1 are provided with an elastic deformation buffer structure, namely the first U-shaped buffer grooves 3 and the second U-shaped buffer grooves 6. When the rubber ring 1 is subjected to force and undergoes elastic deformation, a certain amount of deformation is absorbed by the buffer groove openings, reducing the amount of deformation at the joint between the rubber ring 1 and the ceramic sheet 5.

[0026] In this embodiment, each tooth block 4 has a mounting groove (not shown in the figure) on its front end face. The ceramic sheet 5 is fixed in the mounting groove, and the upper end face of the ceramic sheet 5 is located above the front end face of the tooth block 4. The thickness of the ceramic sheet 5 is not less than 7mm, the depth of the mounting groove is not less than 6mm, the surface of the ceramic sheet 5 has a large roughness, and the rubber wraps the ceramic sheet 5 on all five sides to maximize the contact area between the rubber and the ceramic sheet 5.

[0027] In this embodiment, the number of second U-shaped buffer grooves 6 is half the number of first U-shaped buffer grooves 3. This is to ensure the wrapping force between the rubber ring 1 and the roller steel pipe. Each second U-shaped buffer groove 6 corresponds to one first U-shaped buffer groove 3, and the center lines of the corresponding second U-shaped buffer groove 6 and the first U-shaped buffer groove 3 are on the same straight line. A buffer hole 7 is symmetrically opened on both sides of each second U-shaped buffer groove 6. The buffer holes 7 are designed to be evenly distributed around the center of the mounting hole 2, which can absorb the deformation and reduce the total weight of the rubber ring 1.

[0028] This embodiment exemplarily illustrates a method for preparing a wear-resistant ceramic rubber ring for belt conveyor idlers, comprising the following steps: S1. Assemble the mold onto the thermoforming machine, such as Figures 2-7As shown, the mold consists of an upper template 104, a middle template 103, a lower template 101, a large core 102, a small core 105, and a positioning pin 107. The lower template 101 has a circular groove 109 at its upper end center corresponding to the mounting hole 2 of the rubber ring 1. A first annular groove 110 is provided around the outer periphery of the circular groove 109, and a first annular stepped surface 111 is formed around the outer ring of the circular groove 109. The large core 102 is installed in the circular groove 109. The large core 102 includes a hollow cylinder 1021 with an outer diameter equal to the inner diameter of the mounting hole 2 of the rubber ring 1. The hollow cylinder 1021... A plurality of axially arranged cylinders 1022 are evenly distributed on the outer periphery, which are used to form the second U-shaped buffer groove 6 of the rubber ring 1; a first through hole 112 with the same outer diameter as the rubber ring is opened in the center of the middle template 103; a plurality of axially arranged U-shaped blocks 115 are evenly distributed on the inner wall of the middle template 103, which are used to form the first U-shaped buffer groove 3 of the rubber ring 1; a groove 116 for installing ceramic sheet 5 is opened axially in the center of the inner wall of the middle template 103 between two adjacent U-shaped blocks 115; and a first annular groove 110 is provided on the lower end face of the middle template 103 to cooperate with the first annular groove 110. The upper end face of the middle template 103 is provided with a second annular protrusion 113 symmetrical to the first annular protrusion 113, and the inner circle of the second annular protrusion 113 is provided with a second annular stepped surface 114; the lower end face of the upper template 104 is provided with a column 117 that cooperates with the hollow cylinder 1021, the lower end face of the column 117 is used to contact the upper end face of the circular groove 109, and the lower end face of the upper template 104 on the outer periphery of the column 117 is provided with a second annular groove 118 that cooperates with the second annular protrusion 113, and the inner circle of the second annular groove 118 is provided with a third annular protrusion 114 that cooperates with the second annular stepped surface 114. 19. Several second through holes 108 are evenly distributed on the upper template 104 of the inner ring of the third annular convex rib 119. A small core is installed in the second through hole 108. The small core is cylindrical. The end of the small core is used to extend to the upper end surface of the lower template to form the buffer hole 7 of the rubber ring 1. A positioning pin hole 106 is opened at one end of the lower template 101, the middle template 103 and the upper template 104. The positioning pin 107 is installed in the positioning pin hole 106. First, the lower template is installed on the hot press molding machine. Then, the middle template 103 and the large core 102 are installed in sequence. Then, the mold is preheated (70-90℃). S2. The middle template 103 is placed in place, and a mold cavity is formed between the outer periphery of the large core 102 and the inner ring of the middle template 103. After weighing the mixed rubber material, it is placed into the mold cavity. At the same time, the ceramic sheet 5 with adhesive is placed into the groove of the middle template 103 and properly squeezed and fixed with rubber material. Finally, the template 104 is assembled, and the small core 105 is installed in the second through hole 108. The upper template 104, middle template 103, and lower template 101 are positioned with positioning pins 107 for molding. The molding parameters are: temperature: 140℃~170℃, pressure: molding pressure 19MPa, exhaust pressure 19.5MPa, molding time: not less than 240 seconds. S3. Demold and grind off the rough edges to obtain the wear-resistant ceramic rubber ring for belt conveyor rollers.

[0029] The technical solutions of the present invention are not limited to the specific embodiments described above. Any technical modifications made in accordance with the technical solutions of the present invention fall within the protection scope of the present invention.

Claims

1. A method for preparing a wear-resistant ceramic rubber ring for belt conveyor idlers, characterized in that, A wear-resistant ceramic rubber ring for belt conveyor idlers includes a rubber ring with a central mounting hole. The outer ring surface of the rubber ring has a plurality of radially distributed first U-shaped buffer grooves, with adjacent first U-shaped buffer grooves forming toothed blocks. The two ends of each first U-shaped buffer groove penetrate the axial end faces of the rubber ring, and a ceramic sheet is fixed to the front end face of each toothed block. The inner ring surface of the rubber ring has a plurality of radially distributed second U-shaped buffer grooves, with the two ends of each second U-shaped buffer groove penetrating the axial end faces of the rubber ring. The number of second U-shaped buffer grooves is half the number of first U-shaped buffer grooves, and each second U-shaped buffer groove corresponds to one first U-shaped buffer groove. The center lines of the corresponding second U-shaped buffer groove and the first U-shaped buffer groove are on the same straight line. A buffer hole is symmetrically opened on both sides of each second U-shaped buffer groove. The preparation method of the wear-resistant ceramic rubber ring for belt conveyor idlers includes the following steps: S1. Assemble the mold onto the hot press molding machine. The mold consists of an upper template, a middle template, a lower template, a large core, a small core, and positioning pins. The center of the upper end face of the lower template has a circular groove corresponding to the mounting hole of the rubber ring. The outer periphery of the circular groove has a first annular groove, and the outer ring of the circular groove has a first annular stepped surface. The large core is installed in the circular groove. The large core includes a hollow cylinder with an outer diameter the same as the inner diameter of the mounting hole of the rubber ring. Several axially arranged cylinders are evenly distributed on the outer periphery of the hollow cylinder, and the cylinders are used to form the second U-shaped buffer groove of the rubber ring. The center of the middle template has a first through hole with the same outer diameter as the rubber ring. Several axially arranged U-shaped blocks are evenly distributed on the inner wall of the middle template. The U-shaped blocks are used to form the first U-shaped buffer groove of the rubber ring. The center of the inner wall of the middle template between two adjacent U-shaped blocks has an axial groove for installing ceramic pieces. The lower end face of the middle template has a groove that mates with the first annular groove. The first annular protrusion, the upper end face of the middle template has a second annular protrusion symmetrical to the first annular protrusion, the inner circle of the second annular protrusion has a second annular stepped surface; the center of the lower end face of the upper template has a column that matches the hollow cylinder, the lower end face of the column is used to contact the upper end face of the circular groove, the lower end face of the upper template around the column has a second annular groove that matches the second annular protrusion, the inner circle of the second annular groove has a third annular protrusion that matches the second annular stepped surface, the upper template of the inner circle of the third annular protrusion has several second through holes evenly distributed, the second through holes are fitted with small cores, the small cores are cylindrical, the ends of the small cores are used to extend to the upper end face of the lower template to form buffer holes for the rubber ring; the lower template, the middle template and the upper template have positioning pin holes at one end, the positioning pins are fitted in the positioning pin holes; first, the lower template is assembled on the hot press forming machine, then the middle template and the large core are installed in sequence, and then the mold is preheated. S2. Place the middle template in place, forming a mold cavity between the outer periphery of the large core and the inner ring of the middle template. Weigh the mixed rubber material and place it into the mold cavity. At the same time, place the ceramic sheet with adhesive applied into the groove of the middle template and fix it with rubber material. Finally, assemble the template and install the small core in the second through hole. Use positioning pins to position the upper template, middle template, and lower template for molding. The molding parameters are: temperature: 140℃~170℃, pressure: molding pressure 19MPa, exhaust pressure 19.5MPa, molding time: not less than 240 seconds. S3. Demold and grind off the rough edges to obtain the wear-resistant ceramic rubber ring for belt conveyor rollers.

2. The method for preparing the wear-resistant ceramic rubber ring for belt conveyor idlers according to claim 1, characterized in that: Each toothed block has a mounting groove on its front end face, and the ceramic sheet is fixed in the mounting groove, with the upper end face of the ceramic sheet located above the front end face of the toothed block.

3. The method for preparing the wear-resistant ceramic rubber ring for belt conveyor idlers according to claim 1, characterized in that: The thickness of the ceramic sheet is not less than 7mm, and the depth of the mounting groove is not less than 6mm.

4. The method for preparing the wear-resistant ceramic rubber ring for belt conveyor idlers according to claim 1, characterized in that: The rubber ring around the outer edge of the mounting hole has several buffer holes evenly distributed.

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