Deviation preventing and rectifying device for horizontal turning belt of belt conveyor

Abstract

The invention discloses a deviation preventing and correcting device for a horizontal turning belt of a belt conveyor, relates to the field of coal mining equipment, and solves the problems that an existing belt conveyor is poor in deviation correcting timeliness, insufficient in environmental adaptability and high in maintenance cost. A carrier roller supporting frame is arranged on a rack, a plurality of carrier rollers are arranged on the carrier roller supporting frame, and a belt is arranged on the carrier rollers; anti-deviation mechanisms are arranged on the left side and the right side of the carrier roller supporting frame respectively; the deviation prevention mechanism comprises a wear-resistant shell, a roller body and a support, one end of the support is connected with the carrier roller supporting frame, the other end of the support is rotationally provided with the roller body, the roller body is in a circular truncated cone shape, and the wear-resistant shell is arranged outside the roller body and makes contact with the belt. According to the method, early-stage accurate identification and active intervention can be realized when the belt has small deviation, and secondary faults such as material scattering can be avoided; the influence of the underground severe environment on the reliability of the system is reduced; abrasion of all parts is reduced, the service life of key parts is prolonged, and maintenance cost is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of coal mining equipment, in particular to a horizontal turning belt anti-deviation and correction device for a belt conveyor. Background Art

[0002] In underground coal mine transportation systems, belt conveyors are the core equipment for continuous material transport. Due to limited space and complex geological conditions in underground tunnels, conveyors often require horizontal curves. However, belt deviation in these curves, caused by factors such as centrifugal force, uneven belt tension distribution, and material overload, is a persistent problem, directly impacting equipment efficiency and safety.

[0003] At present, the following technical means are mainly used in this field for anti-deviation and correction:

[0004] Mechanical roller angle adjustment technology uses tilted or tapered rollers to passively correct belt deviations using friction generated by belt misalignment. However, this method suffers from response lag (it requires a certain amount of misalignment to be effective), fixed angle adjustment that cannot adapt to dynamic working conditions, and excessive belt misalignment that can easily cause belt edge wear.

[0005] Electronic sensor monitoring + hydraulic correction system: This system uses a photoelectric sensor to detect belt position and a hydraulic cylinder to drive a steering roller for active correction. While this technology enables dynamic adjustment, the high humidity and dusty environment underground leads to a high sensor false alarm rate, high hydraulic system maintenance costs, and explosion safety risks.

[0006] Mechanical limit stopper device: Fixed stoppers are installed on both sides of the belt to provide rigid position limits. Although this method is simple in structure, it is a passive defense measure. Long-term contact friction causes severe wear of the stoppers and aggravates belt edge wear, shortening the belt life.

[0007] The existing technology has the following defects:

[0008] Poor timeliness of deviation correction: The mechanical deviation correction device can only respond effectively when the belt deflects significantly, which can cause secondary faults such as material spillage and belt tearing.

[0009] Insufficient environmental adaptability: Electronic sensors have a high malfunction rate under high humidity and dust concentration conditions, seriously affecting system reliability;

[0010] High maintenance costs: The retaining wheel and belt edge are severely worn, which leads to high maintenance costs. Replacement operations require downtime, affecting production continuity. Summary of the Invention

[0011] To address the aforementioned issues of poor belt conveyor deviation correction timeliness, insufficient environmental adaptability, and high maintenance costs associated with existing belt conveyors, this invention proposes a belt conveyor horizontal turning belt deviation prevention and correction device. This device can accurately identify and proactively intervene when even minor belt deviations occur, preventing secondary failures such as material spillage. It also mitigates the impact of the harsh underground environment on system reliability, reduces component wear, and extends the life of key components, reducing maintenance costs.

[0012] The present invention proposes a belt conveyor horizontal turning belt anti-deviation and correction device, which specifically includes a roller support frame, a plurality of rollers, an anti-deviation mechanism and a frame, wherein the roller support frame is provided on the frame, a plurality of rollers are provided on the roller support frame, and a belt is provided on the roller; the left and right sides of the roller support frame are respectively provided with anti-deviation mechanisms; the anti-deviation mechanism includes a wear-resistant shell, a roller body and a bracket, one end of the bracket is connected to the roller support frame, and the other end is rotatably provided with a roller body, the roller body is in a frustum shape and is provided with a wear-resistant shell on the outside, and the wear-resistant shell is in contact with the belt.

[0013] Furthermore, the roller body includes an outer hard shell, an elastic deformation layer and an inner hard shell. The outer hard shell, the elastic deformation layer and the inner hard shell are connected in sequence from the outside to the inside. The inner hard shell is mounted on the bracket, and the outer hard shell is connected to the wear-resistant outer shell.

[0014] Furthermore, the elastic deformation layer is a honeycomb structure or a corrugated sandwich structure.

[0015] Furthermore, the elastic deformation layer is made of silicone rubber or polyurethane.

[0016] Furthermore, a step structure 1 is provided on the bracket, and the step structure 1 cooperates with the inner hard shell to limit the roller body; two bearings are provided between the inner hard shell and the bracket.

[0017] Furthermore, a second step structure is provided on the bracket, and a bearing rests on the second step structure; a sleeve is provided between the two bearings; a stop washer is provided at the end of the bracket, and the stop washer limits the other bearing.

[0018] Furthermore, the anti-deflection mechanism also includes an end cover, which is sleeved on the bracket and connected to the wear-resistant shell.

[0019] Furthermore, it also includes a correction system, which includes several hydraulic cylinders, one end of the hydraulic cylinder is connected to the ground through a self-locking rotating device, and the other end is connected to the roller support frame; the roller support frame and the frame are connected to each other through a self-locking rotating device.

[0020] Furthermore, the deviation correction system also includes a plurality of deviation monitoring sensors, and the plurality of deviation monitoring sensors are arranged on the roller support frame.

[0021] The beneficial effects of the belt conveyor horizontal turning belt anti-deviation and correction device described in the present invention are:

[0022] (1) The present invention relates to a belt conveyor horizontal turning belt anti-deviation and correction device. The deviation monitoring sensor can detect a small deviation and trigger adjustment. The deviation correction response time is greatly reduced, thereby avoiding secondary faults such as material spillage and belt tearing. The anti-deviation mechanism constrains the belt to prevent it from deflecting. The hydraulic cylinder and the rotatable self-locking device are used to coordinate the control to improve the adjustment accuracy of the roller lifting angle and reduce the lateral deviation of the belt. After the roller is lifted, the belt is reset by gravity, thereby achieving high-precision active deviation correction.

[0023] (2) The belt conveyor horizontal turning belt anti-deviation and correction device described in the present invention has strong environmental adaptability; the overall design adopts a fully mechanical explosion-proof design, uses a self-locking rotation device and anti-deviation mechanism without electronic components, and has a protection level of IP67, which is suitable for underground environments with high humidity and high dust concentration; it has good impact resistance, and the multi-layer buffering and vibration-absorbing structure of the anti-deviation mechanism makes the impact load attenuation rate ≥80%, effectively suppressing the instantaneous deviation of the belt and greatly improving the life of the roller.

[0024] (3) The present invention relates to a belt conveyor horizontal turning belt anti-deviation and correction device, wherein the wear-resistant outer shell is made of high-chromium cast iron or high-manganese steel, and the average annual replacement frequency is reduced, thereby significantly reducing maintenance costs; a dovetail groove or spring lock is designed on the outer side of the wear-resistant outer shell for easy replacement, and the material is stainless steel with a hard chromium plated surface or sprayed tungsten carbide, which can resist coal gangue wear and corrosive gases, thereby extending the service life. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The drawings constituting a part of this application are used to provide a further understanding of the present invention. The illustrative embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0026] In the attached figure:

[0027] Figure 1 It is a schematic diagram of the three-dimensional structure of a belt conveyor horizontal turning belt deviation prevention and correction device according to the present invention;

[0028] Figure 2 This is an isometric view of a smoke absorption unit of a belt conveyor horizontal turning belt deviation prevention and correction device according to the present invention;

[0029] Figure 3 This is a three-dimensional structural diagram of a smoke and dust absorption unit of a belt conveyor horizontal turning belt deviation prevention and correction device according to the present invention;

[0030] Figure 4It is a cross-sectional view of a smoke absorption unit of a belt conveyor horizontal turning belt deviation prevention and correction device according to the present invention;

[0031] Among them: 1- self-locking rotating device, 2- hydraulic cylinder, 3- roller support frame, 4- roller, 5- anti-deviation mechanism, 6- belt, 7- frame, 8- wear-resistant shell, 9- thrust ball bearing, 10- stop washer, 11- sleeve, 12- roller body, 13- fixing bolt, 14- end cover, 15- bracket, 16- outer hard shell, 17- elastic deformation layer, 18- inner hard shell. DETAILED DESCRIPTION

[0032] The following will clearly and completely describe the technical solutions of the present invention in conjunction with the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0033] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," "outer," and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0034] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0035] In addition, the technical features involved in different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0036] Specific implementation method 1: See Figures 1-4The present embodiment is described in detail. The belt conveyor horizontal turning belt anti-deviation and correction device described in the present embodiment specifically includes a roller support frame 3, a plurality of rollers 4, an anti-deviation mechanism 5 and a frame 7, wherein the frame 7 is provided with a roller support frame 3, a plurality of rollers 4 are provided on the roller support frame 3, and a belt 6 is provided on the roller 4; the roller support frame 3 is provided with an anti-deviation mechanism 5 on both sides thereof; the anti-deviation mechanism 5 includes a wear-resistant shell 8, a roller body 12, an end cover 14 and a bracket 15, one end of the bracket 15 is connected to the roller support frame 3 by welding, bolt connection or quick release buckle, and the other end is rotatably provided with a roller body 12, the roller body 12 is in a truncated cone shape and is provided with a wear-resistant shell 8 on the outside to form a roller structure, the wear-resistant shell 8 is in contact with the belt 6, and a movable gap is provided between the inside of the wear-resistant shell 8 and the roller body 12 and the end of the bracket 15; the end cover 14 is mounted on the bracket 15 and is connected to the wear-resistant shell 8 by a fixing bolt 13 to prevent the wear-resistant shell 8 from falling off. The roller's structural axis is perpendicular to the belt's travel direction, and its outer surface is mounted at a 15° angle to the belt's direction of travel. The roller assembly, consisting of the wear-resistant housing 8, the roller body 12, and the end caps 14, overlaps the idler 4 by 30 mm. The roller's wear-resistant housing 8 is cast from high-manganese steel, with a 3 mm thick tungsten carbide overlay welded onto the working surface, achieving a surface friction coefficient of 0.45. The wear-resistant housing 8 can also be constructed from ultra-high molecular weight polyethylene (UHMWPE) or ceramic composite material (Al2O3-TiC).

[0037] The roller body 12 comprises an outer hard shell 16, an elastically deformable layer 17, and an inner hard shell 18. The outer hard shell 16, elastically deformable layer 17, and inner hard shell 18 are sequentially connected from the outside inward. The inner hard shell 18 is mounted on the bracket 15, and the outer hard shell 16 is connected to the wear-resistant outer shell 8. The bracket 15 is provided with a first step structure, which cooperates with the inner hard shell 18 to limit the position of the roller body 12. Two thrust ball bearings 9 are disposed between the inner hard shell 18 and the bracket 15. The two thrust ball bearings 9 are installed in the bracket 15 with an interference fit, and the roller body 12 is then installed in the thrust ball bearings 9 with an interference fit. The bracket 15 is provided with a second step structure, with one thrust ball bearing 9 resting on the second step structure. A sleeve 11 is disposed between the two thrust ball bearings 9. A retaining washer 10 is disposed at the end of the bracket 15 to limit the position of the other thrust ball bearing 9. When the belt 6 deviates and touches the outer inclined surface of the wear-resistant shell 8, the outer inclined surface of the roller generates a lateral component of force to push the belt 6 back to the center. At the same time, the wear-resistant shell 8 pushes the outer hard shell 16, and the outer hard shell 16 drives the elastic deformation layer 17 to elastically deform to avoid hard impact, such as Figure 4 shown.

[0038] The outer hard shell 16 features a dovetail groove or spring lock for easy replacement of the wear-resistant outer shell 8. It is made of stainless steel with a hard chrome plated or tungsten carbide spray coating. It can also be made of hardened tool steel (SKD11) with a TD treatment (titanium carbide coating, HV2800). The inner hard shell 18 is constructed of forged aluminum alloy (7075-T6) with a hard anodized surface (HV ≥ 400). The three-layer structure is connected through a process of plasma cleaning, primer coating, microporous anchoring, and RTV high-temperature vulcanization bonding, meeting the high load, corrosion, and long life requirements of downhole equipment.

[0039] The elastic deformation layer 17 is a honeycomb structure or a corrugated sandwich structure, and the material is reinforced silicone rubber. Reinforced silicone rubber has excellent temperature resistance (-60 to 250°C), chemical corrosion resistance (resistant to strong acids and alkalis), good biocompatibility, and is suitable for harsh environments. The compressive strength after reinforcement is 15-25MPa, which is sufficient to cope with the load of 200-1500N caused by the deviation of the belt conveyor. In addition, silicone rubber itself has excellent hydrolysis resistance and aging resistance, and is suitable for high humidity environments. The rebound rate is high (90-98%) and recovery is fast. In addition, silicone rubber has good flame retardant properties and meets the explosion-proof requirements of coal mines. It can reliably cope with complex working conditions underground and ensure the long-term and stable operation of equipment.

[0040] The elastic deformation layer 17 can be made of high-elastic polyurethane (PU) or thermoplastic polyurethane (TPU). When using high-elastic polyurethane, the roller body 12 can be manufactured using the following process: laser texturing + silane coupling pretreatment → mold positioning and glue injection + high-temperature vulcanization → demolding and hole repair + tolerance control. When using thermoplastic polyurethane, the roller body can be manufactured using the following process: carbon fiber nylon inner layer + TPU gradient layer + ceramic reinforced outer layer → high-temperature layered printing + gradient fusion.

[0041] The belt conveyor horizontal turning belt anti-deviation and correction device described in the present invention also includes a correction system, which includes a plurality of hydraulic cylinders 2. A hydraulic cylinder 2 is arranged at intervals of 15 meters along the conveying direction. One end of the hydraulic cylinder 2 is rotatably connected to the ground through a self-locking rotating device 1, and the other end is connected to the roller support frame 3; the roller support frame 3 and the frame 7 are rotatably connected through the self-locking rotating device 1; the hydraulic cylinder 2 can adjust the lifting angle of the roller support frame 3, and then lock the hydraulic cylinder 2 and the roller support frame 3 through the self-locking rotating device 1, and by lifting one side of the roller support frame 3, the belt 6 is reset under the action of gravity.

[0042] The correction system also includes several deviation monitoring sensors. Each deviation monitoring sensor and hydraulic cylinder 2 form a correction unit. The present invention utilizes a forward-mounted monitoring node configuration. The deviation monitoring sensors corresponding to each correction unit utilize a feedforward deployment strategy. These sensors are mounted on the roller support frame 3, 5 meters upstream of the hydraulic cylinder 2 (dynamically calibrated based on the belt's running speed), forming a forward-looking monitoring network. This design enables early detection of belt 6 deviation trends. The monitoring sensors are suitable for use in the harsh underground environment.

[0043] At the same time, a micro-progressive adjustment mode is adopted: when the monitoring sensor detects that the deviation has reached the set value, the PID control of the correction unit is immediately used to coordinate the hydraulic rod and the rotary self-locking device to accurately adjust the lifting angle to achieve effective correction of the belt deviation. The adjustment process adopts an incremental control strategy, and the single adjustment amplitude is controlled at a smaller amount to avoid system oscillations caused by excessive intervention. In this embodiment, the detection rod of the deviation monitoring sensor maintains a 20mm gap with the edge of the belt 6. A signal is triggered when the belt offset exceeds 15mm. After receiving the signal from the deviation monitoring sensor, the hydraulic cylinder 2 starts the multi-stage adjustment mode: the primary adjustment extends the piston rod at a speed of 2mm / s, and raises the lifting angle by 3° through the roller support frame 3.

[0044] A multi-stage coordinated deviation correction process is employed: the downstream deviation correction unit uses the corresponding deviation sensor to obtain real-time information about the upstream adjustment status and perform compensatory fine-tuning. Through progressive adjustment by multiple deviation correction units, the lateral deviation of the belt is ultimately brought within the standard range. In this embodiment, the deviation monitoring sensor of the downstream deviation correction unit monitors the belt status after upstream adjustment in real time. When it detects that there is still a deviation of more than 5mm, compensatory adjustment is automatically initiated, with the adjustment amplitude being 60% of the adjustment by the upstream unit. If improvement in deviation is detected, the downstream adjustment amplitude is gradually reduced until the belt is fully back on track. If the deviation does not improve, the downstream adjustment amplitude is gradually increased until the deviation improves, at which point it is gradually reduced.

[0045] To summarize the above implementation cases, the belt conveyor horizontal turning belt anti-deviation and correction device described in the present invention can trigger adjustment when a small deviation occurs through the deviation monitoring sensor set up, and the correction response time is greatly reduced, avoiding secondary faults such as material spillage and belt tearing; the belt 6 is constrained by the anti-deviation mechanism to prevent the belt 6 from deflecting; the hydraulic cylinder 2 and the rotary self-locking device 1 are coordinated to control the roller lifting angle adjustment accuracy, and the lateral deviation of the belt 6 becomes smaller. After the roller is raised, the belt 6 is reset by gravity, realizing high-precision active correction. The belt conveyor horizontal turning belt anti-deviation and correction device described in the present invention has strong environmental adaptability; the overall design adopts a fully mechanical explosion-proof design, adopts a self-locking rotary device and anti-deviation mechanism without electronic components, and has a protection level of IP67, which is suitable for underground environments with high humidity and high dust concentration; the impact resistance is good, and the multi-layer buffering and vibration absorbing structure of the anti-deviation mechanism makes the impact load attenuation rate ≥80%, effectively suppressing the instantaneous deviation of the belt and greatly improving the life of the roller. The present invention describes a belt conveyor horizontal turning belt anti-deviation and correction device, in which the wear-resistant outer shell 8 is made of high-chromium cast iron or high-manganese steel, and the average annual replacement frequency is reduced, significantly reducing maintenance costs; a dovetail groove or spring lock is designed on the outer side of the wear-resistant outer shell 8 for easy replacement, and the material is stainless steel with a hard chrome-plated or tungsten carbide-sprayed surface, which can resist coal gangue wear and corrosive gases, thereby extending service life.

[0046] The specific embodiments described above further illustrate the objectives, technical solutions, and beneficial effects of the present invention. It should be understood that the above description is merely a specific embodiment of the present invention and is not intended to limit the invention. Reasonable combinations of the features described in the above embodiments are also possible. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention shall be included in the scope of protection of the present invention.

Claims

1. A belt conveyor horizontal turning belt anti-deviation and correction device, characterized by: The invention comprises a roller support frame (3), a plurality of rollers (4), an anti-deviation mechanism (5) and a frame (7); the frame (7) is provided with a roller support frame (3), the roller support frame (3) is provided with a plurality of rollers (4), and the rollers (4) are provided with a belt (6); the left and right sides of the roller support frame (3) are respectively provided with an anti-deviation mechanism (5); the anti-deviation mechanism (5) comprises a wear-resistant shell (8), a roller body (12) and a bracket (15); one end of the bracket (15) is connected to the roller support frame (3), and the other end is rotatably provided with a roller body (12); the roller body (12) is in a truncated cone shape and is provided with a wear-resistant shell (8) on the outside; the wear-resistant shell (8) is in contact with the belt (6).

2. The belt conveyor horizontal turning belt anti-deviation and correction device according to claim 1 is characterized in that: The roller body (12) comprises an outer hard shell (16), an elastic deformation layer (17) and an inner hard shell (18); the outer hard shell (16), the elastic deformation layer (17) and the inner hard shell (18) are connected in sequence from the outside to the inside; the inner hard shell (18) is mounted on the bracket (15); and the outer hard shell (16) is connected to the wear-resistant outer shell (8).

3. The belt conveyor horizontal turning belt anti-deviation and correction device according to claim 2 is characterized in that: The elastic deformation layer (17) is a honeycomb structure or a corrugated sandwich structure.

4. The belt conveyor horizontal turning belt deviation prevention and correction device according to claim 3 is characterized in that: The elastic deformation layer (17) is made of silicone rubber or polyurethane.

5. The belt conveyor horizontal turning belt anti-deviation and correction device according to claim 3 or 4, characterized in that: The bracket (15) is provided with a step structure 1, which cooperates with the inner hard shell (18) to limit the roller body (12); two bearings are provided between the inner hard shell (18) and the bracket (15).

6. The belt conveyor horizontal turning belt deviation prevention and correction device according to claim 5 is characterized in that: The bracket (15) is provided with a second step structure, and a bearing rests on the second step structure; a sleeve (11) is provided between the two bearings; a stop washer (10) is provided at the end of the bracket (15), and the stop washer (10) limits the position of the other bearing.

7. The belt conveyor horizontal turning belt anti-deviation and correction device according to claim 1 is characterized in that: The anti-deflection mechanism (5) further comprises an end cover (14), which is sleeved on the bracket (15) and connected to the wear-resistant shell (8).

8. The belt conveyor horizontal turning belt anti-deviation and correction device according to claim 1 is characterized in that: The device also includes a deviation correction system, which includes a plurality of hydraulic cylinders (2). One end of the hydraulic cylinder (2) is rotationally connected to the ground through a self-locking rotating device (1), and the other end is connected to a roller support frame (3); the roller support frame (3) and the frame (7) are rotationally connected through the self-locking rotating device (1).

9. The belt conveyor horizontal turning belt anti-deviation and correction device according to claim 8, characterized in that: The deviation correction system further comprises a plurality of deviation monitoring sensors, which are arranged on the roller support frame (3).

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