High belt replacement method and system

Abstract

The invention relates to the technical field of industrial conveying equipment maintenance, and discloses a high-position belt replacement method and system.The system comprises a support, a roller shaft and a parallel carrier roller assembly, the roller shaft penetrates through a new belt roller and is erected on the support, the parallel carrier roller assembly is installed at a tail roller of a belt, and efficient connection and traction of the new belt and the old belt are achieved; according to the method, the problem of deviation during replacement of the high belt is solved, the belt can be replaced under the condition of no shutdown or short-time shutdown, the replacement time is shortened, the material transportation cost caused by shutdown is reduced, and the replacement efficiency and safety of the high belt are improved; and meanwhile, the parallel carrier roller assemblies are matched with the rubber anti-skid layers, the problem of belt deviation can be effectively solved, the transverse offset is controlled within a reasonable range, and solid support is provided for stability and reliability in the replacement process.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of industrial conveying equipment maintenance, in particular to a high-altitude belt replacement method and system. BACKGROUND

[0002] In industrial production, high-altitude belts (such as overhead conveying belts erected in workshops) are key equipment for material conveying, and are widely used in metallurgy, coking and other fields. Such belts are usually closed in a ring shape and are sleeved on multiple roller bodies such as rollers and tail rollers, and are circulated by a driving device to complete long-distance conveying of materials such as coke.

[0003] However, in the maintenance and replacement process of high-altitude belts, the traditional method has the following technical problems: (1) The problem of belt deviation after lifting is prominent: when replacing, the new and old belts need to be connected, and the new belt is pulled into the preset path by the driving system. However, due to the high installation position and large span of the high-altitude belt, which is usually more than 5m from the ground, and the unstable running state of the belt during replacement, the belt is prone to tilt, fall or lateral deviation due to gravity imbalance and uneven traction. Deviation not only hinders the smooth entry of the new belt into the roller body, but also may cause edge wear and tearing of the belt, and even cause equipment jamming, seriously affecting replacement efficiency and job safety; (2) Long replacement time and high downtime cost: the traditional replacement method requires manual repeated adjustment of the belt position to correct the deviation, and a single replacement often takes more than 4 hours. Since high-altitude belts are usually public equipment, such as two anti-coke belts in a coking workshop, material conveying needs to be stopped during downtime, resulting in the accumulation of coke and other materials on the ground, which requires the use of two single-dump trucks for loading and two cars for transportation to handle the fallen materials. According to the calculation of 800 yuan per shift per single-dump truck and 150 yuan per car, long downtime will result in high equipment rental and material transfer costs; (3) Insufficient stability of auxiliary support: the erection of the new belt roller relies on manual or simple supports, which makes it difficult to ensure the parallelism and height consistency of the new belt roller with the old belt roller, resulting in uneven stress on the new belt during traction, further exacerbating the deviation problem and increasing the workload of secondary adjustment.

[0004] Therefore, in view of the deviation problem during replacement of high-altitude belts, a method and supporting system are needed to quickly locate and stably constrain the running track of the belt, and to reduce the replacement time, in order to solve the problems of low efficiency, high cost and poor safety in traditional technology. SUMMARY

[0005] The purpose of the present application is to overcome the deficiencies in the prior art, provide a high place belt replacement method and system, to solve the problem of deviation when replacing the high place belt, shorten the replacement time, reduce the material transportation cost caused by downtime, improve the efficiency and safety of high place belt replacement, and is suitable for the replacement operation of multiple public overhead belts in the workshop.

[0006] To achieve the above purpose, the technical scheme adopted by the present application is: In a first aspect, a high place belt replacement method is provided, comprising: placing a new belt drum on a support through a roller shaft, ensuring that the new belt drum is aligned with the position of the old belt to be replaced; installing a parallel roller assembly at the tail roller, so that the upper roller of the parallel roller assembly is above the belt and the lower roller is below the belt; connecting one end of the old belt to one end of the new belt to form a continuous connection body; starting the belt driving system to move the old belt along the running path, and the connection body passes between the upper roller and the lower roller; after the new belt completely enters the preset path, disconnect the new and old belts, and then fix and connect the two ends of the new belt to form a ring-shaped closed structure, completing the replacement.

[0007] Optionally, the old belt and the new belt are connected through a detachable connector, the connector includes two clamping plates that cooperate with each other, the connection between the old belt and the new belt is located between the two clamping plates, and the two clamping plates are connected by a fastener.

[0008] Optionally, during belt operation, the upper roller abuts against the surface of the belt to limit its upward warping, the lower roller supports the bottom of the belt to prevent it from falling downward, and the upper roller and the lower roller both reduce the friction of belt operation through rolling contact.

[0009] Optionally, during belt replacement, the running state data of the belt is obtained, and the positions of the upper roller and the lower roller are adjusted through the running state data.

[0010] Optionally, the running state data includes lateral displacement data and longitudinal tension data.

[0011] In a second aspect, a high place belt replacement system is provided for implementing the high place belt replacement method of the first aspect, comprising a support, a parallel roller assembly, and a roller shaft for supporting a new belt drum, the roller shaft is rotatably installed on the support, the parallel roller assembly is installed at the tail roller, and the parallel roller assembly includes an upper roller and a lower roller parallel to the tail roller.

[0012] Optionally, it further includes a monitoring device for monitoring the running state of the belt, the monitoring device includes a displacement sensor and a tension sensor, the displacement sensor is used to monitor the lateral displacement of the belt, and the tension sensor is used to monitor the longitudinal tension of the belt.

[0013] Optionally, the surface of the upper supporting roller and the lower supporting roller is provided with an anti-skid layer made of rubber material.

[0014] Compared with the prior art, the present application has the following advantages: (1) In the present application, the problem of deviation of the belt during replacement of the belt at a high position is solved by passing the belt between the upper and lower supporting rollers, and the replacement of the belt can be completed without shutdown or with short-time shutdown, thereby shortening the replacement time, reducing the cost of material transportation due to shutdown, and improving the efficiency and safety of the replacement of the belt at a high position. (2) In the present application, the parallel supporting roller assembly cooperates with the rubber anti-skid layer to effectively solve the problem of deviation of the belt, and control the transverse deviation within a reasonable range, thereby providing a solid support for the stability and reliability of the replacement process. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 is a flowchart of the method for replacing the belt at a high position in the embodiment of the present application; Figure 2 is a structural schematic diagram of the belt replacement system at a high position in the embodiment of the present application; Among them, 1, support; 2, roller shaft; 3, new belt drum; 4, lower supporting roller; 5, upper supporting roller. DETAILED DESCRIPTION

[0016] The present application will now be further described in detail in conjunction with the drawings and embodiments, which are all simplified schematic diagrams, and only illustrate the basic structure of the present application in a schematic manner, and thus only show the components related to the present application.

[0017] In the prior art, the belt for industrial conveying equipment is mostly in a closed loop structure, and the two ends of the belt are connected to form a closed loop through vulcanization or mechanical joint; the belt driving system includes a driving drum, a motor and a reducer, a tensioning device and a supporting roller set; the output torque of the working motor is reduced and increased in torque by the reducer, and then the driving drum rotates; due to the friction between the belt and the drum, the drum drives the belt to make continuous circular motion, thereby realizing material conveying; the tensioning device is used to provide constant tension to ensure the friction between the belt and the drum, and the supporting roller set is used to reduce the sag of the belt.

[0018] Example one, as Figure 1 and Figure 2As shown, the high-position belt replacement system provided by the present application comprises a support 1, a roller shaft 2, a parallel roller assembly and a monitoring device. After the roller shaft 2 passes through a new belt roller 3, the roller shaft 2 and the new belt roller 3 can be erected on the support 1 by a forklift. The parallel roller assembly is installed at the tail roller of the high-position belt and is in line with the belt, and comprises an upper roller 5 and a lower roller 4 which are parallel to the tail roller and form a channel for the belt to pass through. The monitoring device is used to monitor the running state of the belt and comprises a displacement sensor and a tension sensor.

[0019] Specifically, the new belt roller 3 is wound with a new belt for replacing the old belt. After the new belt roller 3 is erected on the support 1 by the roller shaft 2, the old belt is partially cut off at a suitable position, usually close to the tail roller, to form two cut ends. Then, the old belt is connected to the new belt at one of the cut ends by a connector. Then, the belt driving system, such as a motor, is started to drive the old belt to move along the conveying path. At the tail roller, the new and old belts pass through the parallel roller assembly to ensure smooth transition. When the new belt completely enters the conveying path, the other end of the old belt is cut off and removed. Finally, the two ends of the new belt are connected (by vulcanization or mechanical joint) to restore the ring-shaped closed structure.

[0020] The upper roller 5 and the lower roller 4 of the parallel roller assembly are used to provide guidance and support at the tail roller. The upper roller 5 prevents the belt from lifting, and the lower roller 4 prevents the belt from falling to avoid the belt from deviating or falling off during the replacement process.

[0021] The displacement sensor is used to monitor the lateral displacement of the belt and is installed on both sides of the belt. It uses the laser ranging principle to monitor the lateral displacement of the belt in real time. The tension sensor is used to monitor the tension of the belt and is embedded in the bearing seat of the roller. It measures the tension distribution of the belt by using a strain gauge.

[0022] Further, the upper roller 5 and the lower roller 4 are installed at the tail roller of the high-position belt by a mounting bracket. The two ends of the roller are connected to the mounting bracket by a knuckle bearing, and an electric cylinder is provided on the mounting bracket to drive the roller to swing, so as to realize the angular adjustment of the roller. The bottom of the mounting bracket is provided with an electric lifting platform which has strong self-locking performance and realizes the adjustment of the angle and height of the roller. During the belt replacement process, the running state of the belt is dynamically monitored, and the position of the roller is adjusted accordingly, so as to ensure the smooth running of the belt during replacement.

[0023] In addition, the surfaces of the upper roller 5 and the lower roller 4 are provided with anti-skid layers made of rubber material. During the belt replacement process, when the new and old belt connecting body passes through the roller, the rubber anti-skid layer can effectively prevent the lateral sliding of the belt caused by uneven traction or gravity, so as to control the lateral displacement of the belt within a reasonable range and significantly reduce the risk of deviation.

[0024] Embodiment two, the application also proposes a high belt replacement method, which is realized by the high belt replacement system disclosed in embodiment one, to solve the deviation problem existing in high belt replacement, shorten the replacement time, reduce the material transportation cost caused by downtime, improve the efficiency and safety of high belt replacement, and is suitable for the replacement operation of multiple public overhead belts in the workshop.

[0025] As shown in Figure 1 and Figure 2 , a high belt replacement method includes new belt roller 3 erection, parallel roller assembly installation, old and new belt connection, belt traction replacement, and new belt fixation. Through the above method, the belt can be replaced without downtime or with short downtime, while ensuring safety and efficiency.

[0026] New belt roller 3 erection: the new belt is pre-wound on the roller, the roller shaft 2 is inserted through the shaft hole of the roller, the roller shaft 2 is lifted by a forklift, the new belt roller 3 is placed stably on the support 1, the position of the support 1 is adjusted to make the axis of the new belt roller 3 parallel to the axis of the old belt, and the position of the new belt roller 3 is aligned with the old belt to be replaced.

[0027] Parallel roller assembly installation: on the frame of the tail roller, the mounting frame of the parallel roller assembly is fixed by bolts, the upper roller 5 is located above the belt, the lower roller 4 is located below the belt, the upper roller 5 abuts against the surface of the belt to limit its upward tilting, the lower roller 4 supports the bottom of the belt to prevent it from falling downward, and the upper roller 5 and the lower roller 4 both reduce the friction of the belt running through rolling contact.

[0028] Old and new belt connection: one end of the old belt is connected with one end of the new belt to form a continuous connection body; the old belt and the new belt are connected through a detachable connector, the connector includes two clamping plates that cooperate with each other, the connection between the old belt and the new belt is located between the two clamping plates, and the two clamping plates are connected through fasteners.

[0029] Specifically, at the cut-off of the old belt near the tail roller side, two clamping plates are used to clamp the end of the old belt and the end of the new belt, and the two clamping plates are firmly fixed together through fastening bolts to ensure that the connection strength is sufficient to pull the new belt.

[0030] Belt traction replacement: start the belt driving system to make the old belt drive the new belt to move along the running path, and the connection body passes between the upper roller 5 and the lower roller 4; start the belt driving motor to make the old belt run at a speed of 0.5 m / s to drive the new belt to move along the path. Observe the running state of the belt during the process, and if there is slight deviation, the installation angle of the roller assembly can be adjusted slightly.

[0031] Wherein, during the belt replacement process, the running state data of the belt is acquired, and the positions of the upper and lower supporting rollers 5 and 4 are adjusted through the running state data; the running state data includes lateral offset data and longitudinal tension data.

[0032] Specifically, the lateral offset data is the left and right offset amount of the belt relative to the preset center line during the running process, which directly reflects whether the belt is deviated; if the offset amount exceeds the threshold value, the direction needs to be corrected by adjusting the angle of the supporting roller, that is, the upper supporting roller 5 is finely adjusted to the offset side, and the lower supporting roller 4 is reversely assisted to avoid the edge of the belt from being worn or deviated from the supporting roller.

[0033] The longitudinal tension data is the tension of the belt during the running process, which is measured by measuring the pressure of the contact point between the belt and the supporting roller through the tension sensor, and it reflects the tightness of the belt; if the local tension is too large, it may cause the belt to stretch and deform; if the tension is too small, the belt is prone to sag. The height of the supporting roller needs to be adjusted to balance the tension and reduce the running resistance by pressing down the upper supporting roller 5 or lifting up the lower supporting roller 4.

[0034] New belt fixation: after the new belt completely enters the preset path, the connection between the new and old belts is disconnected, and then the two ends of the new belt are fixedly connected to form a closed loop structure, and the replacement is completed. When the new belt completely passes through all the rollers and forms a closed loop, the machine is stopped and the connection between the new and old belts is disconnected, and the two ends of the new belt are connected by vulcanization using a vulcanizing machine, the vulcanization temperature is 145°C, the pressure is 1.5MPa, and the holding time is 30min, thereby completing the replacement.

[0035] When the new belt is completely wrapped around the roller to form a closed loop by the traction of the old belt, the connection point of the new and old belts will return to the initial connection position or the preset cutting point as the belt runs. At this time, the machine is stopped and the connection between the new and old belts is disconnected, and the new belt has been independently sleeved on each roller body to form a stable running loop structure; while the old belt loses the traction of the new belt and the system tension, it will naturally relax, and most of its length has been pushed out or taken away from the original roller body path, only the remaining part is still on the roller body. At this time, the old belt can be manually peeled off from the rollers, supporting rollers and other components, because the old belt has no tension constraint, it only needs to be pulled out along the axial or radial direction of the roller body to complete the removal.

[0036] In summary, the present application provides a high-altitude belt replacement method and system, which passes the roller shaft 2 through the new belt roller 3 and sets it on the support 1 by the forklift, installs a parallel supporting roller assembly at the tail roller of the belt, and realizes efficient connection and traction of the new and old belts. This method solves the problem of deviation during high-altitude belt replacement, can shorten the replacement time by about 2 hours, reduce the material transportation cost caused by shutdown (about 900 yuan per time), is suitable for replacement of multiple public high-altitude belts in the workshop, and significantly improves the operation efficiency and economy.

[0037] In the description of the present application, it is to be understood by the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second" and the like are only for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined with "first", "second" and the like can explicitly or implicitly include one or more of the features. In the description of the present application, unless otherwise specified, the meaning of "a plurality of" is two or more.

[0038] In the description of the present application, it should be noted that, unless otherwise specified and limited, the terms "mounting", "connecting", "connecting" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium, it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood through specific circumstances.

[0039] The above is based on the ideal embodiment of the present application, through the above description, relevant personnel can make various changes and modifications without deviating from the scope of the technical idea of the present application. The technical scope of the present application is not limited to the contents of the specification, and the technical scope must be determined according to the scope of claims.

Claims

1. A method of changing a belt at height, characterized in that, The application relates to a belt replacement device. The new belt roller is placed on the support through the roller shaft, and the new belt roller is aligned with the position of the old belt to be replaced; The parallel roller assembly is installed at the tail roller, and the upper roller of the parallel roller assembly is located above the belt, and the lower roller is located below the belt; One end of the old belt is connected with one end of the new belt to form a continuous connection body; The belt driving system is started, the old belt drives the new belt to move along the running path, and the connection body passes between the upper roller and the lower roller; After the new belt completely enters the preset path, the connection between the new belt and the old belt is disconnected, and the two ends of the new belt are fixedly connected to form a ring-shaped closed structure, and the replacement is completed.

2. The overhead belt replacement method according to claim 1, characterized by, The old belt and the new belt are connected through a detachable connector, the connector comprises two clamping plates matched with each other, the connection between the old belt and the new belt is located between the two clamping plates, and the two clamping plates are connected through fasteners.

3. The overhead belt replacement method of claim 2, wherein, During belt running, the upper roller abuts against the surface of the belt to limit the upward lifting of the belt, the lower roller supports the bottom of the belt to prevent the downward falling of the belt, and the upper roller and the lower roller are in rolling contact to reduce the friction of the belt running.

4. The overhead belt replacement method of claim 1, wherein During belt replacement, the running state data of the belt is acquired, and the positions of the upper roller and the lower roller are adjusted through the running state data.

5. The method of claim 4, wherein, The running state data comprises transverse displacement data and longitudinal tension data.

6. An overhead belt replacement system for carrying out the overhead belt replacement method according to any one of claims 1 to 5, characterized in that The application relates to a belt replacement device.

7. The overhead belt replacement system of claim 6, wherein, The monitoring device comprises a displacement sensor and a tension sensor, the displacement sensor is used for monitoring the transverse displacement of the belt, and the tension sensor is used for monitoring the longitudinal tension of the belt.

8. The overhead belt replacement system of claim 7, wherein, The surfaces of the upper roller and the lower roller are provided with antiskid layers made of rubber materials.

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