A belt conveyor linkage type groove angle self-adaptive steady-state energy-saving device

Abstract

The application discloses a linkage type groove angle self-adaptive steady-state energy-saving device of a belt conveyor and belongs to the technical field of belt conveyors. The device comprises a plurality of groups of self-adaptive steady-state energy-saving devices arranged on both sides of an upper carrier roller frame. Each group of devices realizes self-adaptive adjustment of a groove angle through the synergistic effect of a movable side wing arm, a main support frame, a torsion spring, a central hinged main shaft, a rotary damper and a micro oil cylinder. All the micro oil cylinders are connected to an energy accumulator through high-pressure hoses to form a pressure community, thereby ensuring linkage of the plurality of groups of carrier rollers and synchronous response to load changes. When the belt conveyor is unloaded, the torsion spring flattens the carrier roller groups to save energy. When the load increases, hydraulic pressure cooperatively deepens the groove angle to stabilize the load. The rotary damper suppresses oscillation caused by sudden load changes. An adaptive deviation rectifying device is arranged at the lower part of the device and can automatically rectify deviation without power. The device effectively solves the problems of high energy consumption, easy deviation and easy wave-shaped deformation of the fixed-groove-angle carrier roller groups and has the remarkable advantages of energy saving, stability, reliability and long service life.

Description

Technical Field

[0001] This invention belongs to the technical field of belt conveyors, specifically relating to a linked trough angle adaptive steady-state energy-saving device for belt conveyors. Background Technology

[0002] Belt conveyors are the core equipment for bulk material conveying, and the performance of their idler sets is crucial. Currently widely used fixed trough angle idler sets have significant drawbacks: First, under no-load or light-load conditions, the conveyor belt is forced to bend, generating unnecessary bending and indentation resistance, leading to high energy consumption. Second, during sudden load changes, the fixed trough angle cannot adapt, easily inducing longitudinal wavy deformation of the conveyor belt, increasing resistance and accelerating fatigue. Third, uneven material loading easily leads to belt misalignment and wear on the belt edges. Existing solutions, such as the lubrication-based resistance reduction scheme in CN222292799U and the laser detection and electric actuation correction scheme in CN120534711A, are mostly limited to the independent operation of a single idler set, failing to address the system-wide wavy deformation and misalignment risks caused by asynchronous operation between multiple idler sets. Therefore, a new type of idler system with coordinated operation and adaptive anti-deformation capabilities is urgently needed. Summary of the Invention

[0003] The purpose of this invention is to solve the above-mentioned technical problems and provide a linked trough angle adaptive steady-state energy-saving device for belt conveyors.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0005] An adaptive steady-state energy-saving device for the trough angle of a belt conveyor includes several sets of adaptive steady-state energy-saving devices, each set of adaptive steady-state energy-saving devices being correspondingly arranged on both sides of the hinged idler group of the belt conveyor.

[0006] The adaptive steady-state energy-saving device includes movable side wings, a main support frame, a torsion spring, a central hinged main shaft, a rotation damper, and a miniature hydraulic cylinder. The main support frame has a U-shaped structure and is vertically fixed on the main support frame base on both sides of the hinged idler roller assembly. The two ends of the central hinged main shaft are hinged to the upper ends of the two side plates of the main support frame. The tail of the miniature hydraulic cylinder is hinged to the lower part of the main support frame. The middle part of the movable side wings is hinged to the central hinged main shaft, and the upper end is connected to the side roller shaft of the hinged idler roller assembly. The end is hinged, and the lower end is hinged to the telescopic rod of the miniature hydraulic cylinder. The torsion spring is set on the central hinged main shaft. The middle protrusion of the torsion spring is locked in the small groove of the movable side wing arm, and the two ends are locked on the inner lugs of the two side plates of the main support frame, so that the movable side wing arm is always subjected to a torque that flattens the hinged roller group. The rotary damper is located on the outer side of the two side plates of the main support frame and is connected to the central hinged main shaft for transmission. A shaft elastic retaining ring is provided between the rotary damper and the central hinged main shaft.

[0007] All the micro cylinders of the aforementioned adaptive steady-state energy-saving devices are interconnected via high-pressure hoses and connected to a common accumulator, forming a hydraulic linkage system.

[0008] Furthermore, the lower part of the main support frame base is also provided with an anti-deviation base, and an adaptive correction device is provided between the main support frame base and the anti-deviation base.

[0009] Furthermore, the adaptive correction device includes an intermediate shaft, a bushing, a thrust ball bearing, two correction shafts, and two self-aligning roller bearings. The intermediate shaft is connected to the bushing via the thrust ball bearing, allowing the main support frame base to rotate around the intermediate shaft. An elastic retaining ring is provided at the interface between the intermediate shaft and the bushing for limiting the movement.

[0010] Furthermore, the adaptive correction device also includes two symmetrically arranged correction shafts and self-aligning roller bearings. The two correction shafts are symmetrically arranged on the anti-deviation bases on the left and right sides of the intermediate shaft. The self-aligning roller bearings are arranged on the upper part of the correction shafts and cooperate with the arc-shaped groove slide of the main support frame base.

[0011] Compared with the prior art, the beneficial effects of the present invention are:

[0012] 1. All the miniature hydraulic cylinders of this invention are connected to the accumulator through a common oil circuit to form a "pressure community". When the local load changes, the pressure change will be transmitted to the entire idler roller device instantly, driving all the movable side wings to move synchronously and in the same direction, so that the trough angle in this area changes smoothly and uniformly. This multi-idler roller group coordinated posture adjustment mechanism fundamentally avoids the problems of longitudinal wave-shaped deformation, stress concentration and material spillage of the conveyor belt caused by the asynchronous movement of a single idler roller, and greatly improves the stability and reliability of operation.

[0013] 2. This invention uses the pre-torque of the torsion spring to automatically flatten the idler roller assembly when unloaded or lightly loaded, so that the conveyor belt maintains a smooth shape, fundamentally eliminating unnecessary bending resistance and idler roller indentation resistance. When the load increases, it can adaptively deepen the trough angle to stabilize the material load. This ability to automatically optimize the trough shape according to the load achieves a significant reduction in operating energy consumption.

[0014] 3. The linkage posture adjustment function of this invention can automatically compensate for the influence of lateral off-center load, suppressing the tendency of belt deviation from the root cause of the load. Combined with the unique adaptive correction device at the bottom, when belt deviation occurs, the entire upper base can automatically rotate around the central axis without power. Through the sliding of the self-aligning roller bearing in the arc groove, a lateral reciprocating correction force is applied to the conveyor belt, realizing continuous self-correction during operation, effectively reducing belt deviation accidents and maintenance workload;

[0015] 4. The rotary damper of this invention provides crucial damping force to the system. When the conveying volume changes abruptly, it can effectively suppress the rapid rotation of the movable arm and the oscillation of the system, absorb impact energy, make the trough angle change process smooth and gentle, avoid the violent shaking of the conveyor belt, and ensure the dynamic stability of the system operation.

[0016] 5. The entire system of this invention adopts the principle of pure mechanical and hydraulic linkage, without the need for external power source and complex electrical control system. It has a robust structure, is resistant to harsh working conditions such as dust and humidity, has strong environmental adaptability, low failure rate, simple maintenance and long service life. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall operation of the present invention;

[0018] Figure 2 This is a schematic diagram of the main structure of a single component of the present invention;

[0019] Figure 3 This is a side view of a single component of the present invention.

[0020] Figure 4 for Figure 2 Sectional view along line AA;

[0021] Figure 5 for Figure 2 Sectional view along the BB direction;

[0022] Figure 6 for Figure 2 C-direction view;

[0023] Figure 7 This is a schematic diagram illustrating the working principle of the miniature hydraulic cylinder and accumulator of the present invention;

[0024] Figure 8 This is a schematic diagram of the torsion spring structure of the present invention;

[0025] Figure 9 This is a schematic diagram of the central hinged spindle structure of the present invention;

[0026] In the diagram: 1-Conveyor belt; 2-Hinged idler assembly; 3-Movable side wing arm; 4-Main support frame; 5-Torsion spring; 6-Central hinged main shaft; 7-Rotation damper; 8-Shaft elastic retaining ring; 9-Miniature hydraulic cylinder; 10-Anti-deviation base; 11-Accumulator; 12-High-pressure hose; 13-Intermediate shaft; 14-Shaft sleeve; 15-Thrust ball bearing; 16-Correction shaft; 17-Self-aligning roller bearing; 18-Arc-shaped groove slide. Detailed Implementation

[0027] The present invention will be further described below with reference to the embodiments and accompanying drawings.

[0028] like Figure 1-9 As shown, a linkage-type trough angle adaptive steady-state energy-saving device for a belt conveyor is disclosed. The standard intermediate frame of the belt conveyor is 6m long, and the interval of the upper idler frames is 1.2m. Five sets of upper idler frames are installed on one set of intermediate frames. The conveyor belt 1 serves as a traction and load-bearing component, conveying bulk materials and applying positive pressure to the hinged idler set 2. The hinged idler set 2 is composed of one intermediate idler, two side rollers, a hinge plate, and a pin connected in series.

[0029] It includes five sets of adaptive steady-state energy-saving devices. Each set of upper idler rollers is equipped with one set of adaptive steady-state energy-saving devices. The adaptive steady-state energy-saving device includes movable side wings 3, main support frame 4, torsion spring 5, central hinged main shaft 6, rotation damper 7, and miniature hydraulic cylinder 9. The main support frame 4 has a "U"-shaped structure and is vertically fixed on the main support frame base on both sides of the hinged idler roller group 2. The two ends of the central hinged main shaft 6 are hinged to the upper ends of the two side plates of the main support frame 4. The tail of the miniature hydraulic cylinder 9 is hinged to the lower part of the main support frame 4. The middle part of the movable side wings 3 is hinged to the central hinged main shaft 6, the upper end is hinged to the end of the side roller shaft of the hinged idler roller group 2, and the lower end is hinged to the telescopic rod of the miniature hydraulic cylinder 9. The torsion spring 5 is a high-strength spring selected after calculation. The spring has a central protrusion that fits into a small groove in the movable side arm 3, and both ends are engaged with the inner lugs on the side plates of the main support frame 4. This ensures that the movable side arm 3 is always subjected to a torque that rotates outward relative to the main support frame 4 around the main shaft, flattening the hinged roller group 2. The rotary damper 7 is bolted to the outer side of the side plates of the main support frame 4 and is engaged with the central hinged main shaft 6 via a key and groove. The rotary damper 7 has a bidirectional damping function. When the conveying volume changes abruptly, the oil inside the rotary damper 7 flows through the small hole, generating resistance. This resistance is fed back to the movable side arm 3 through the central hinged main shaft 6, suppressing its rapid rotation, preventing the conveyor belt 1 from oscillating, and making the operation more stable. A shaft elastic retaining ring 8 is provided between the rotary damper 7 and the central hinged main shaft 6.

[0030] Each set of adaptive steady-state energy-saving devices has a micro cylinder 9 connected to an accumulator 11 via a high-pressure hose 12. When the conveyor belt 1 carrying a certain amount of material passes the first set of idler rollers, it forces the movable side arm 3 to rotate, causing the piston rod of the micro cylinder 9 to be lifted. The oil flows through the common pipeline to the accumulator 11. Since all the cylinder chambers are connected, a "pressure community" is formed. This local pressure change will be quickly transmitted to the entire set of idler rollers, causing the movable arms of the entire set of idler rollers to press down slightly in the same direction at the same time. This makes the groove angle in this area uniformly deepen and the belt surface height uniformly decrease slightly, but maintains a smooth slope transition rather than an abrupt "wave". This can greatly reduce the pressure resistance between the conveyor belt 1 and the idler rollers, making the operation more energy-efficient and stable. The accumulator 11 plays the role of absorbing pressure pulses and stabilizing the system pressure.

[0031] like Figure 7 As shown, the specific working principle of the "pressure community" is as follows: The miniature hydraulic cylinder 9 consists of a rod chamber and a rodless chamber. The rod chambers and rodless chambers of adjacent hydraulic cylinders are connected in series via high-pressure hoses 12. The rodless chambers and rod chambers of the first and last hydraulic cylinders are connected to the accumulator 11 via high-pressure hoses 12, forming a closed loop. When the load changes abruptly, the piston rod of hydraulic cylinder 1 is lifted, and the oil in the rod chamber is squeezed into the rodless chamber of hydraulic cylinder 2 through the high-pressure hose 12. The rod chamber of hydraulic cylinder 2 is compressed, and the hydraulic rod is lifted. Similarly, all subsequent hydraulic cylinders are lifted in sequence, causing all movable side wings 3 to retract inward in sequence, thereby unifying the pressure community. 1. The groove corner of this area is smoothly deepened. The accumulator 11 has an oil chamber and an oilless chamber. Nitrogen gas with a certain pressure is filled through the oilless chamber, which is like an "air cushion". When the pressure suddenly increases, it is compressed to absorb excess oil and impact energy. When the pressure decreases, the gas expands and discharges the oil to maintain the system pressure balance. When there is no load or light load, there is a certain pressure inside the accumulator 11, which makes the pressure of the two chambers of all cylinders equal and the height of the oil rods of all cylinders almost the same. With the help of the torsion spring 5, the movable side wing arm 3 is in the position that allows the belt to be flattened.

[0032] The main support frame base is also equipped with an anti-deviation base 10 at its lower part. An adaptive correction device is provided between the main support frame base and the anti-deviation base 10. The adaptive correction device includes an intermediate shaft 13, a bushing 14, a thrust ball bearing 15, two correction shafts 16, and two self-aligning roller bearings 17. The upper half of the intermediate shaft 13 is inserted into the middle of the main support frame base, and the lower half is inserted into the middle of the anti-deviation base 10 through the bushing 14. The intermediate shaft 13 and the bushing 14 are connected by the thrust ball bearing 15. A shaft elastic retaining ring 8 is provided at the interface between the intermediate shaft 13 and the bushing 14. The two correction shafts 16 are symmetrically arranged on the anti-deviation bases 10 on the left and right sides of the intermediate shaft 13. The correction shafts 16 are provided with elastic retaining rings 8 at both ends. The self-aligning roller bearings 17 are arranged on the upper part of the correction shafts 16. The upper end of the self-aligning roller bearings 17 cooperates with the arc-shaped groove slide 18 of the main support frame base. When the conveyor belt 1 deviates, the main support frame 4 can rotate around the intermediate shaft 13 of the anti-deviation base 10 without power. The self-aligning roller bearings 17 slide around the intermediate shaft 13 in the arc-shaped groove slide 18, which plays a certain role in correction and ensures the safe and reliable operation of the conveyor belt 1.

[0033] Working process of the invention

[0034] 1. No-load or light-load operating conditions:

[0035] At this time, the material on the conveyor belt 1 is very light or unloaded. Under the pre-torque of the torsion spring 5, the movable side wing arm 3 is subjected to a force that makes it rotate outward. This force acts on the side roller of the hinged idler group through the upper hinge point, overcoming the slight resistance of the micro cylinder 9, and lifting the entire idler group 2 upward, making it tend to flatten. The conveyor belt 1 thus passes through in a flat or shallow trough shape, minimizing bending and indentation resistance, thereby achieving energy-saving operation. The rotary damper 7 is in standby mode in this state.

[0036] 2. Increased load condition:

[0037] As the material carried by the conveyor belt 1 increases, the positive pressure exerted by the weight of the material on the hinged idler group 2 increases. This pressure is transmitted to the upper end of the movable side arm 3, generating a torque that overcomes the pre-torque of the torsion spring and causes the movable arm to retract inward. The movable side arm 3 rotates around the central hinged main shaft 6, and its lower end lifts the piston rod of the micro cylinder 9, forcing the oil in the cylinder into the common pipeline and accumulator 11 through the high-pressure hose 12. Since the oil circuits of all cylinders are interconnected, a "pressure community" is formed. This local pressure increase will be quickly transmitted to the cylinders of the same group and even adjacent idler groups, causing all movable side arms 3 to retract inward in a coordinated and synchronous manner, thereby uniformly and smoothly deepening the trough angle in this area to better contain and transport materials. During this process, the accumulator 11 absorbs pressure pulses to maintain stable system pressure. The rotation damper 7 provides damping when the movable arm rotates to prevent excessively fast movements from causing impacts or oscillations, ensuring a smooth trough angle change process.

[0038] When the material is transported on the conveyor belt 1, the movable side wings 3 of the entire set of idlers in this area will press down slightly in the same direction at the same time, so that the trough angle of this area is uniformly deepened and the belt surface height is uniformly slightly reduced, but the slope transition is smooth rather than abrupt "waves". This can greatly reduce the pressure resistance between the conveyor belt 1 and the idlers, making the operation more energy-efficient and stable.

[0039] 3. Sudden load change condition:

[0040] When the conveying volume suddenly increases significantly, such as when a large amount of material suddenly falls or decreases, it can easily cause system oscillation. At this time, the rotary damper 7 plays a key role. The rapid rotation tendency of the movable side arm 3 will drive the central hinged main shaft 6 to rotate rapidly. The oil inside the rotary damper 7 is forced to flow through the small holes, generating a huge damping force. This resistance is fed back to the movable side arm 3 through the main shaft, effectively suppressing its rapid movement and absorbing impact energy. This allows the hinged idler roller group 2 to smoothly transition to a new equilibrium position, avoiding large-scale up-and-down fluctuations and wave-like deformation of the conveyor belt 1, and ensuring the stability of operation.

[0041] 4. Deviation in operation:

[0042] If the conveyor belt 1 deviates to one side due to material eccentricity or other reasons, the deviated conveyor belt 1 will exert additional lateral pressure on the idler roller group on that side. For a single idler roller group, this pressure will act on the movable side wing arm 3 and the main support frame 4. For the entire system, due to the special connection design of the upper and lower parts, the pressure on the deviated side will cause the base of the main support frame to be subjected to an overturning moment. This moment causes the base to tend to rotate around the intermediate shaft 13. The base slides laterally in the arc-shaped groove slide 18 of the anti-deviation base 10 through the self-aligning roller bearing 17 below it. At the same time, the thrust ball bearing 15 between the intermediate shaft 13 and the bushing 14 allows the base to deflect slightly. This series of actions constitutes a powerless adaptive correction process, generating a reverse correction force on the deviated conveyor belt 1, helping it return to the center position and achieving automatic correction.

[0043] The specific values ​​and quantities given in this embodiment are merely typical application scenarios and specific examples selected to clearly illustrate and demonstrate the technical solution of the present invention. This does not mean that the present invention is limited to this specific size or quantity configuration. All variations and implementations based on the core principle of the present invention—that is, forming a pressure community with the accumulator through interconnected oil circuits to achieve adaptive adjustment of the trough angle of multiple sets of idler rollers—regardless of their specific size or quantity, fall within the protection scope claimed by the present invention.

Claims

1. A linkage-type adaptive steady-state energy-saving device for belt conveyors, characterized in that, It includes several sets of adaptive steady-state energy-saving devices, each set of adaptive steady-state energy-saving devices is correspondingly set on both sides of the hinged idler group (2) of the belt conveyor; The adaptive steady-state energy-saving device includes a movable side wing arm (3), a main support frame (4), a torsion spring (5), a central hinged main shaft (6), a rotation damper (7), and a miniature hydraulic cylinder (9). The main support frame (4) has a "U"-shaped structure and is vertically fixed on the main support frame base on both sides of the hinged roller group (2). The two ends of the central hinged main shaft (6) are hinged to the upper ends of the two side plates of the main support frame (4). The tail of the miniature hydraulic cylinder (9) is hinged to the lower part of the main support frame (4). The middle part of the movable side wing arm (3) is hinged to the central hinged main shaft (6), the upper end is hinged to the end of the side roller shaft of the hinged roller group (2), and the lower end is hinged to the telescopic rod of the miniature hydraulic cylinder (9). The torsion spring (5) The torsion spring (5) is mounted on the central hinged spindle (6). The middle protrusion of the torsion spring (5) is locked in the small groove of the movable side wing arm (3), and the two ends are locked on the inner lugs of the two side plates of the main support frame (4). This ensures that the movable side wing arm (3) is always subjected to a torque that flattens the hinged roller group (2). The rotary damper (7) is located on the outer side of the two side plates of the main support frame (4) and is connected to the central hinged spindle (6) for transmission. The rotary damper (7) is provided with a shaft elastic retaining ring (8) between the central hinged spindle (6) and the central hinged spindle (6) for limiting. With the pre-torque of the torsion spring (5), the hinged roller group (2) is automatically flattened when unloaded or lightly loaded. When the load increases, the groove angle can be adaptively deepened to stabilize the material load. All the micro cylinders (9) of the adaptive steady-state energy-saving device are interconnected through high-pressure hoses (12) and connected to a common accumulator (11) to form a hydraulic linkage system, so that all the active side wings move synchronously and in the same direction.

2. The linked trough angle adaptive steady-state energy-saving device for a belt conveyor according to claim 1, characterized in that, The main support frame base is also provided with an anti-deviation base (10) at the bottom, and an adaptive correction device is provided between the main support frame base and the anti-deviation base (10).

3. The linked trough angle adaptive steady-state energy-saving device for a belt conveyor according to claim 2, characterized in that, The adaptive correction device includes an intermediate shaft (13), a bushing (14) and a thrust ball bearing (15). The intermediate shaft (13) is connected to the bushing (14) through the thrust ball bearing (15), so that the main support frame base can rotate around the intermediate shaft (13). An elastic retaining ring (8) for shaft is provided at the interface between the intermediate shaft (13) and the bushing (14).

4. The linked trough angle adaptive steady-state energy-saving device for a belt conveyor according to claim 3, characterized in that, The adaptive correction device also includes two symmetrically arranged correction shafts (16) and self-aligning roller bearings (17). The two correction shafts (16) are symmetrically arranged on the anti-deviation bases (10) on the left and right sides of the intermediate shaft (13). The self-aligning roller bearings (17) are arranged on the upper part of the correction shafts (16). The self-aligning roller bearings (17) cooperate with the arc-shaped groove slide (18) of the main support frame base.

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