Device and method for replacing belt carrier roller in sintering operation area

Abstract

The invention belongs to the technical field of maintenance of sintering operation equipment, and relates to a replacing device for a belt carrier roller in a sintering operation area. A first adjusting nut and a second adjusting nut are in threaded connection with the two ends of a two-way screw correspondingly, and an upper shear fork mechanism and a lower shear fork mechanism are arranged at the upper end and the lower end of the two-way screw correspondingly; the lower ends of two scissor forks of the upper scissor fork mechanism and the upper ends of two scissor forks of the lower scissor fork mechanism are connected to the first adjusting nut and the second adjusting nut respectively, the upper ends of the two scissor forks of the upper scissor fork mechanism and the lower ends of the two scissor forks of the lower scissor fork mechanism are connected into the upper sliding groove block and the lower sliding groove block in a sliding mode through sliding blocks respectively, and the lower sliding groove block is embedded in the base. A supporting head is installed at the top of the upper sliding groove block, and an adjusting handle is installed at the end of the two-way screw rod. The invention further relates to a replacement method for the belt carrier roller in the sintering operation area. The purposes of reducing labor, improving quality, improving efficiency and being safe in belt carrier roller replacement operation in the sintering operation area are achieved.

Description

Technical Field

[0001] This invention belongs to the field of sintering equipment maintenance technology, and relates to a special tool, particularly a replacement device and method for belt idlers in sintering operation areas. Background Technology

[0002] In sintering operations in industries such as steel and metallurgy, belt conveyor systems are the core equipment for material transport, operating under harsh conditions of high temperature, high dust, and high corrosion. Idler rollers, as key supporting components of belt conveyor systems, must continuously withstand material impact, material adhesion and scaling, and chemical corrosion, resulting in a failure rate far higher than under normal operating conditions. Regular replacement and maintenance are necessary to ensure the normal operation of the conveyor system.

[0003] Currently, the industry mainly uses traditional manual methods to replace idler rollers in the sintering operation area. This method has the following significant defects and shortcomings: 1. High manpower requirements: Each replacement operation requires 3-4 people to work together. One person needs to lift the belt directly with their back to make room for the replacement of the idler roller, while the other 2-3 people are responsible for disassembling the old idler roller and installing the new idler roller. The labor cost is high. 2. Significant safety hazards: Manual carrying of belts can easily lead to lumbar muscle injuries for operators. In addition, temporary blocks such as bricks and wooden stakes are often used to support the belts during the operation. These blocks are prone to breaking off, which may cause accidents such as crushing or bumping injuries to operators. 3. Low operating efficiency: Due to the manual operation method and safety risk control, a single roller replacement takes 30-40 minutes. Frequent shutdowns for replacement will seriously affect the continuity of sintering production and reduce overall production efficiency.

[0004] Therefore, developing a special tool for replacing idler rollers that can reduce manpower requirements, eliminate safety hazards, and improve replacement efficiency has become a key requirement for solving the maintenance problems of belt conveyor systems in sintering operation areas. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a replacement device and method for belt idlers in sintering operation areas that is scientifically and rationally designed, saves manpower and effort, is safe and reliable, improves work efficiency, and is easy to implement.

[0006] The technical problem solved by this invention is achieved through the following technical solution: A replacement device for belt idlers in a sintering operation area is characterized by comprising a base, a bidirectional screw, an upper scissor fork structure, a lower scissor fork structure, a first adjusting nut, a second adjusting nut, an upper sliding groove block, a lower sliding groove block, a support head, and an adjusting handle. The first adjusting nut and the second adjusting nut are threadedly connected to both ends of the bidirectional screw. An upper scissor fork mechanism and a lower scissor fork mechanism are respectively provided at the upper and lower ends of the bidirectional screw. The lower ends of the two scissor forks of the upper scissor fork mechanism and the upper ends of the two scissor forks of the lower scissor fork mechanism are respectively connected to the first adjusting nut and the second adjusting nut. The upper ends of the two scissor forks of the upper scissor fork mechanism and the lower ends of the two scissor forks of the lower scissor fork mechanism are slidably connected to the upper sliding groove block and the lower sliding groove block via sliders. The lower sliding groove block is embedded in the base. A support head is installed on the top of the upper sliding groove block. An adjusting handle is installed at the end of the bidirectional screw.

[0007] Furthermore, it also includes a limiting cap, which is installed at the other end of the bidirectional screw.

[0008] Moreover, both the upper and lower sliding blocks are blocks with grooves on their end faces, and two sliders are slidably installed in the grooves, with the sliders fixed to the ends of the scissor fork.

[0009] Moreover, the support head has an arc-shaped structure that adapts to the curvature of the lower surface of the belt.

[0010] Furthermore, the base has a structure with a mounting groove at the bottom.

[0011] Furthermore, it also includes auxiliary installation mechanisms, which are symmetrically installed at both ends of the base. The auxiliary installation mechanisms include a mounting plate, an outer sleeve, an inner insert post, a mounting head, a clamping plate, and a clamping screw. A mounting plate is welded to one end of the outer sleeve, and the mounting plate is connected to the side of the base by screws. An inner insert post that extends and retracts inside the outer sleeve is provided inside the outer sleeve. A mounting head is welded to the end of the inner insert post. The mounting head has an inverted U-shaped structure. A clamping screw is threaded to the outside of the mounting head, and a clamping plate placed inside the mounting head is rotatably installed on the clamping screw.

[0012] A method for replacing belt idlers in a sintering operation area, characterized by the following steps: Step 1: Inspect the belt idler replacement device to ensure that all components are in good condition; confirm that the belt conveyor system is in a stopped state. Step 2: Select the appropriate installation method for the belt idler replacement device according to the structure of the belt conveyor system to be operated; make the arc surface of the support head completely fit with the lower surface of the belt, and ensure that the support heads of the two belt idler replacement devices are at the same horizontal height to avoid tilting during the belt support process. Step 3: Simultaneously crank the adjusting handle clockwise to drive the bidirectional screw to rotate, causing the first adjusting nut and the second adjusting nut to move towards each other. The scissor mechanism extends and drives the support head to rise slowly. When the support head rises to the point where the belt and the idler roller are initially separated, stop cranking, use a feeler gauge to check the gap between the idler roller and the belt, and observe the belt tension change. If local wrinkles appear on the belt, fine-tune the adjusting handle of one of the devices to restore the belt to a flat surface. Continue to rotate the adjusting handle synchronously until the feeler gauge shows that the gap between the idler roller and the belt reaches 30mm. At this point, the idler roller is completely unloaded and has no load. Stop supporting and record the number of rotations of the adjusting handle for reference during subsequent reset. Step 4: Replace the belt idler rollers; Step 5: After the belt idler replacement is completed, the belt idler replacement device is removed.

[0013] Furthermore, the method for selecting the appropriate installation method of the belt idler replacement device based on the structure of the belt conveyor system to be operated is as follows: If there is a roller mounting bracket in the middle of the lower part of the roller to be replaced, and the width of the mounting bracket is compatible with the mounting groove of the base, then place the two replacement devices symmetrically on both sides of the roller, so that the mounting groove of the base is snapped into the roller mounting bracket, and press the base to ensure that the protective pad is tightly fitted to the mounting bracket. If there is no available mounting bracket under the idler roller, use an auxiliary positioning mechanism for installation. Place the two replacement devices under the belt on both sides of the idler roller, pull out the inner insert post so that the U-shaped opening of the mounting head is aligned with the crossbeam of the belt conveyor frame, and insert the limit pin to fix the length of the inner insert post; manually tighten the top screw on the outside of the mounting head until the top plate is in contact with the surface of the frame to ensure that the device is not loose.

[0014] Moreover, after the belt idler is replaced, the method for removing the belt idler replacement device is as follows: two operators simultaneously turn the adjustment handle counterclockwise to slowly lower the support head. During the process, they closely observe the contact state between the idler and the belt. When the belt contacts the idler, they slow down the descent speed until the support head and the belt are completely separated. If the base-mounted method is used, the belt roller replacement device can be directly removed from the roller mounting frame; If an auxiliary positioning mechanism is used, first loosen the tightening screw, pull out the limit pin, retract the inner insert into the outer sleeve, and then remove the belt roller replacement device.

[0015] The advantages and beneficial effects of this invention are as follows: 1. This device and method for replacing belt idlers in the sintering operation area involves placing the tool at the bottom of the idler to be replaced, and then using a hand crank to adjust the handle. Under the action of the scissor fork, the belt is lifted up, avoiding the problems of labor-intensive, unsafe, and inefficient replacement caused by manually lifting the belt in the existing technology.

[0016] 2. The replacement device and method for belt idlers in the sintering operation area are designed with an arc-shaped support head that matches the arc of the lower surface of the belt, thus avoiding stress concentration and damage to the belt.

[0017] 3. The replacement device and method for belt idlers in the sintering operation area facilitates installation through the auxiliary installation mechanism. When there is an idler mounting frame at the lower middle position of the belt to be replaced, the present invention can be installed on the idler mounting frame through the mounting groove provided on the base; otherwise, it can be mounted on the frame on both sides of the belt conveyor frame through the auxiliary installation mechanism to achieve the purpose of replacing idlers. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of Embodiment 1 of the present invention; Figure 2 This is a schematic diagram of the structure of Embodiment 2 of the present invention.

[0019] Figure Labels 1-Limit cap, 2-First adjusting nut, 3-Upper sliding block, 4-Sliding groove, 5-Upper scissor structure, 6-Slider, 7-Support head, 8-Double-actuated screw, 9-Second adjusting nut, 10-Lower scissor structure, 11-Base, 12-Adjusting handle, 13-Tightening screw, 14-Tightening plate, 15-Mounting head, 16-Inner insert post, 17-Outer sleeve, 18-Mounting plate. Detailed Implementation

[0020] The present invention will be further described in detail below through specific embodiments. The following embodiments are merely descriptive and not limiting, and should not be used to limit the scope of protection of the present invention.

[0021] A replacement device and method for belt idlers in a sintering operation area, characterized in that it includes a base 11, a bidirectional screw 8, an upper scissor fork structure 5, a lower scissor fork structure 10, a first adjusting nut 2, a second adjusting nut 9, an upper sliding groove block 3, a lower sliding groove block, a support head 7, and an adjusting handle 12. The first adjusting nut and the second adjusting nut are threadedly connected to both ends of the bidirectional screw. An upper scissor fork mechanism and a lower scissor fork mechanism are respectively provided at the upper and lower ends of the bidirectional screw. The lower ends of the two scissor forks of the upper scissor fork mechanism and the upper ends of the two scissor forks of the lower scissor fork mechanism are respectively connected to the first adjusting nut and the second adjusting nut. The upper ends of the two scissor forks of the upper scissor fork mechanism and the lower ends of the two scissor forks of the lower scissor fork mechanism are slidably connected to the upper sliding groove block and the lower sliding groove block via sliders. The lower sliding groove block is embedded in the base. A support head is installed on the top of the upper sliding groove block. An adjusting handle is installed at the end of the bidirectional screw.

[0022] To prevent the adjusting nut (the first adjusting nut in this embodiment) located on the outside from coming off, the present invention designs a limiting cap 1, which is installed at the other end of the bidirectional screw.

[0023] Both the upper and lower sliding blocks are blocks with sliding grooves 4 on their end faces. Two sliders 6 are slidably installed in the sliding grooves and are fixed to the ends of the scissor fork.

[0024] The support head has an arc-shaped structure that adapts to the curvature of the lower surface of the belt, thus avoiding stress concentration that could damage the belt.

[0025] This invention provides two installation methods: one is installation via a base, and the other is installation via an auxiliary installation mechanism.

[0026] In Example 1, the base has a structure with a mounting groove on the bottom. A protective pad is placed inside the mounting groove to increase the friction between the base and the mounting bracket, ensuring stable installation.

[0027] In Example 2, auxiliary installation mechanisms are symmetrically installed at both ends of the base. The auxiliary installation mechanisms include an installation plate 18, an outer sleeve 17, an inner insert post 16, an installation head 15, a top clamping plate 14, and a top clamping screw 13. An installation plate is welded to one end of the outer sleeve, and the installation plate is connected to the side of the base by screws. An inner insert post that extends and retracts inside the outer sleeve is provided inside the outer sleeve. The outer sleeve and the inner insert post are fixed by a limiting pin. An installation head is welded to the end of the inner insert post. The installation head is an inverted U-shaped structure. A top clamping screw is threaded to the outside of the installation head, and a top clamping plate placed inside the installation head is rotatably installed on the top clamping screw.

[0028] When in use, place two of the present inventions in the center of the bottom of the belt, on both sides of the replacement idler roller, so that the support point is less than 50mm away from the idler roller, and each support head is supported on the lower part of the belt. Pull out the inner inserts on both sides, insert the mounting head into the frame, and tighten it with the top plate; Then, manually crank the adjusting handles on both tools simultaneously. The first and second adjusting nuts move in opposite directions, raising the support head and thus lifting the belt. Each rotation of the adjusting handle raises the belt by 1.2mm, allowing for fine-tuning until the idler roller is completely unloaded. After the belt is lifted 5-10mm, observe the change in belt tension. Then continue lifting until the gap between the idler and the belt reaches 30mm (use a feeler gauge to check the gap). Ensure that the idler is unloaded before you can replace the idler.

[0029] An innovative method for replacing belt idlers in a sintering work area includes the following steps: Step 1, Preparation before the task (takes approximately 5 minutes) Step 1.1 Equipment Inspection: Confirm that the scissor lift mechanism of the replacement device extends and retracts flexibly, the adjustment handle rotates smoothly, and the tightening screws of the auxiliary installation mechanism are intact. Clean the dust and debris from the surface of the support head and the mounting groove of the base. Check that the feeler gauge (range 0-50mm), wrench (M8, M12 specifications), gloves, goggles and other tools and protective equipment are complete. Step 1.2 Operating Condition Confirmation: Stop the belt conveyor system where the idler to be replaced is located, disconnect the power supply and hang a "Equipment under maintenance, do not start" warning sign; remove loose materials and dust around the idler, confirm that there are no sharp objects on the belt surface, measure the diameter, length and installation spacing of the idler to be replaced, and ensure that the curvature of the support head of the replacement device is compatible with the belt.

[0030] Step 2, Device installation and positioning stage (approximately 8 minutes) Step 2.1, Installation method selection: If there is a roller mounting bracket in the middle of the lower part of the roller to be replaced, and the width of the mounting bracket is compatible with the mounting groove of the base, then place the two replacement devices symmetrically on both sides of the roller (the distance between the support head and the edge of the roller is ≤50mm), so that the mounting groove of the base is snapped into the roller mounting bracket, and press the base to ensure that the protective pad is tightly fitted to the mounting bracket; If there is no available mounting bracket under the idler roller, use an auxiliary positioning mechanism for installation: place the two replacement devices under the belt on both sides of the idler roller, pull out the inner insert post so that the U-shaped opening of the mounting head is aligned with the crossbeam of the belt conveyor frame, insert the limit pin to fix the length of the inner insert post; manually tighten the top screw on the outside of the mounting head until the top plate is in contact with the surface of the frame to ensure that the device is not loose. Step 2.2, support head alignment: Adjust the position of the replacement device so that the arc-shaped surface of the support head is fully in contact with the lower surface of the belt, ensuring that the support heads of the two devices are at the same horizontal height, and avoiding tilting during the belt support process.

[0031] Step 3, belt support stage (takes approximately 3-5 minutes) Step 3.1, Initial Support: Two operators stand next to the two changing devices respectively, and simultaneously turn the adjusting handle clockwise to drive the bidirectional screw to rotate, so that the first adjusting nut and the second adjusting nut move towards each other. The scissor fork mechanism extends and drives the support head to rise slowly. For each rotation of the adjusting handle, the support head rises by 1.2mm. During the process, the rising speed of the two devices is kept consistent to avoid the belt being stressed on one side.

[0032] Step 3.2, Gap detection: When the support head rises to the point where the belt and idler roller are initially separated (about 5-10mm), stop shaking, use a feeler gauge to check the gap between the idler roller and the belt, and observe the belt tension change. If local wrinkles appear on the belt, fine-tune the adjustment handle of one of the devices to restore the belt to flatness.

[0033] Step 3.3, final support: Continue to rotate the adjusting handle synchronously until the feeler gauge shows that the gap between the idler roller and the belt reaches 30mm. At this time, the idler roller is completely unloaded and has no load. Stop the support and record the number of rotations of the adjusting handle for reference during subsequent reset.

[0034] Step 4, Idler roller replacement stage (takes approximately 8-10 minutes) Step 4.1, old idler removal: One operator uses a wrench to remove the bearing seat bolts at both ends of the idler and pulls the old idler out axially, taking care to avoid the material adhering to the idler surface falling onto the belt or replacement device; clean the dust and debris inside the idler mounting base, check the flatness of the mounting base, and if there is wear or deformation, grind and repair it.

[0035] Step 4.2, New Idler Installation: Place the new idler (model same as the old idler) smoothly into the mounting base, adjust the axial position of the idler to ensure that the center line of the idler is perpendicular to the belt running direction; tighten the bearing seat bolts, and control the bolt tightening torque to 25-30 N·m to avoid over-tightening which may cause bearing damage or over-loosening which may cause abnormal noise during idler operation.

[0036] Step 5, belt reset and device removal stage (takes approximately 5 minutes) Step 5.1, slow belt reset: Two operators simultaneously turn the adjusting handle counterclockwise to slowly lower the support head. During the process, they closely observe the contact state between the idler roller and the belt. Once the belt contacts the idler roller, the descent speed is reduced until the support head and the belt are completely separated (the descent height corresponds to the number of rotations of the adjusting handle during the top support stage).

[0037] Step 5.2, Device Removal: If the base clamping method is used, directly remove the replacement device from the roller mounting frame; if the auxiliary positioning mechanism is used, first loosen the tightening screw, pull out the limit pin, retract the inner insert into the outer sleeve, and then remove the replacement device; clean the dust and debris on the surface of the device, check the condition of each component, and if problems such as wear of the support head buffer layer or jamming of the adjustment mechanism are found, perform timely maintenance.

[0038] Step 6, Post-assignment verification stage (approximately 2 minutes) Step 6.1, no-load test run: Start the belt conveyor system and run it without load for 5 minutes. Observe the rotation status of the newly installed idler rollers to confirm that there are no abnormal noises or deviations and that the contact between the idler rollers and the belt is uniform. Step 6.2, Load Verification: Restore material transmission of the belt conveyor system, run for 10 minutes, check the temperature rise of the idler rollers (surface temperature ≤ ambient temperature + 40℃) and vibration value (≤ 0.15mm / s). After confirming that there are no abnormalities, remove the warning sign and the operation is completed.

[0039] Although embodiments and drawings of the present invention have been disclosed for illustrative purposes, those skilled in the art will understand that various substitutions, variations and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A replacement device for belt idlers in a sintering operation area, characterized in that: The device includes a base, a bidirectional screw, an upper scissor mechanism, a lower scissor mechanism, a first adjusting nut, a second adjusting nut, an upper sliding block, a lower sliding block, a support head, and an adjusting handle. The first adjusting nut and the second adjusting nut are threaded to both ends of the bidirectional screw. An upper scissor mechanism and a lower scissor mechanism are respectively provided at the upper and lower ends of the bidirectional screw. The lower ends of the two scissor forks of the upper scissor mechanism and the upper ends of the two scissor forks of the lower scissor mechanism are respectively connected to the first adjusting nut and the second adjusting nut. The upper ends of the two scissor forks of the upper scissor mechanism and the lower ends of the two scissor forks of the lower scissor mechanism are slidably connected to the upper sliding block and the lower sliding block via sliders. The lower sliding block is embedded in the base. A support head is installed on the top of the upper sliding block. An adjusting handle is installed at the end of the bidirectional screw.

2. The replacement device for belt idlers in a sintering operation area according to claim 1, characterized in that: It also includes a limit cap, which is installed at the other end of the bidirectional screw.

3. A replacement device for belt idlers in a sintering operation area according to claim 1, characterized in that: Both the upper and lower sliding blocks are blocks with sliding grooves on their end faces. Two sliders are slidably installed in the sliding grooves and are fixed to the ends of the scissor fork.

4. A replacement device for belt idlers in a sintering operation area according to claim 1, characterized in that: The support head has an arc-shaped structure that is adapted to the curvature of the lower surface of the belt.

5. A replacement device for belt idlers in a sintering operation area according to claim 1, characterized in that: The base has a mounting groove at the bottom.

6. A replacement device for belt idlers in a sintering operation area according to claim 1, characterized in that: It also includes auxiliary installation mechanisms, which are symmetrically installed at both ends of the base. The auxiliary installation mechanisms include a mounting plate, an outer sleeve, an inner insert post, a mounting head, a clamping plate, and a clamping screw. A mounting plate is welded to one end of the outer sleeve, and the mounting plate is connected to the side of the base by screws. An inner insert post that extends and retracts inside the outer sleeve is provided. A mounting head is welded to the end of the inner insert post. The mounting head is an inverted U-shaped structure. A clamping screw is threaded to the outside of the mounting head. A clamping plate placed inside the mounting head is rotatably installed on the clamping screw.

7. A method for replacing belt idlers in a sintering operation area, characterized in that: This method is implemented based on the replacement device for belt idlers in the sintering operation area as described in any one of claims 1-6, and includes the following steps: Step 1: Inspect the belt idler replacement device to ensure that all components are in good condition; confirm that the belt conveyor system is in a stopped state. Step 2: Select the appropriate installation method for the belt idler replacement device according to the structure of the belt conveyor system to be operated; make the arc surface of the support head completely fit with the lower surface of the belt, and ensure that the support heads of the two belt idler replacement devices are at the same horizontal height to avoid tilting during the belt support process. Step 3: Simultaneously crank the adjusting handle clockwise to drive the bidirectional screw to rotate, causing the first adjusting nut and the second adjusting nut to move towards each other. The scissor mechanism extends and drives the support head to rise slowly. When the support head rises to the point where the belt and the idler roller are initially separated, stop cranking, use a feeler gauge to check the gap between the idler roller and the belt, and observe the belt tension change. If local wrinkles appear on the belt, fine-tune the adjusting handle of one of the devices to restore the belt to a flat surface. Continue to rotate the adjusting handle synchronously until the feeler gauge shows that the gap between the idler roller and the belt reaches 30mm. At this point, the idler roller is completely unloaded and has no load. Stop supporting and record the number of rotations of the adjusting handle for reference during subsequent reset. Step 4: Replace the belt idler rollers; Step 5: After the belt idler replacement is completed, the belt idler replacement device is removed.

8. A method for replacing belt idlers in a sintering operation area according to claim 7, characterized in that: The method for selecting the appropriate installation method for the belt idler replacement device based on the structure of the belt conveyor system to be operated is as follows: If there is a roller mounting bracket in the middle of the lower part of the roller to be replaced, and the width of the mounting bracket is compatible with the mounting groove of the base, then place the two replacement devices symmetrically on both sides of the roller, so that the mounting groove of the base is snapped into the roller mounting bracket, and press the base to ensure that the protective pad is tightly fitted to the mounting bracket. If there is no available mounting bracket under the idler roller, use an auxiliary positioning mechanism for installation. Place the two replacement devices under the belt on both sides of the idler roller, pull out the inner insert post so that the U-shaped opening of the mounting head is aligned with the crossbeam of the belt conveyor frame, and insert the limit pin to fix the length of the inner insert post; manually tighten the top screw on the outside of the mounting head until the top plate is in contact with the surface of the frame to ensure that the device is not loose.

9. A method for replacing belt idlers in a sintering operation area according to claim 7, characterized in that: After the belt idler roller is replaced, the method for removing the belt idler roller replacement device is as follows: Two operators simultaneously turn the adjustment handle counterclockwise to slowly lower the support head. During the process, they closely observe the contact state between the idler roller and the belt. When the belt contacts the idler roller, they slow down the descent speed until the support head and the belt are completely separated. If the base-mounted method is used, the belt roller replacement device can be directly removed from the roller mounting frame; If an auxiliary positioning mechanism is used, first loosen the tightening screw, pull out the limit pin, retract the inner insert into the outer sleeve, and then remove the belt roller replacement device.

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