Split tensioning roller device of conveying belt bucket elevator

Abstract

The invention discloses a split tensioning roller device of a conveying belt bucket elevator, which relates to the technical field of material conveying in the electric power industry, and comprises a main shaft, a wheel core and at least three groups of wear-resistant modules, the wheel core is coaxially and fixedly connected with the main shaft, and mounting positions matched with the wear-resistant modules are uniformly arranged on the periphery of the wheel core; the wear-resistant module comprises a connecting plate and a plurality of wear-resistant strips. The wear-resistant strip is designed by adopting a gradient structure of the base material and the wear-resistant layer, the high toughness of the base material can effectively resist ash impact and avoid breakage of the wear-resistant strip, and the high-hardness wear-resistant layer on the surface can greatly enhance the wear resistance, remarkably prolong the service life of the wear-resistant strip and reduce equipment faults caused by failure of the wear-resistant strip; meanwhile, the asymmetric trapezoidal groove lines on the surface of the wear-resistant strip are designed at special angles and planned in the direction, so that the problem of dust accumulation is solved, belt transmission unbalance caused by dust accumulation is prevented, stable friction force between the belt and the rollers can be guaranteed, and the belt is prevented from slipping.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of material conveying in the power industry, in particular to a split tensioning roller device of a conveyor belt bucket elevator. BACKGROUND

[0002] In the material conveying system of the power industry, the TGD type steel wire rope core conveyor belt bucket elevator is one of the key equipment, and the core function of the tensioning roller thereof is to provide stable tensioning force for the operation of the elevator to ensure the stable transmission of the belt. At present, the mainstream tensioning roller on the market is manufactured by using the integral riveting and turning machining process, and the integral structure is a solid steel structure which cannot be disassembled, and the key wear part is usually made of single Hadfield 400 steel.

[0003] However, such a traditional tensioning roller has significant defects in actual application, which are as follows:

[0004] 1. High risk of failure due to wear: There are a large number of ash in the operating environment of the elevator, which causes abrasion to the wear-resistant strip for a long time, resulting in rapid failure of the wear-resistant strip. When the wear-resistant strip is worn to a certain extent, the transmission balance between the belt and the roller will be damaged, which is easy to cause the belt to deviate, and in severe cases, it may cause the belt to jam and tear, directly affecting the safe and stable operation of the elevator.

[0005] 2. High difficulty and cost of maintenance: When the wear-resistant strip is worn and causes the belt to deviate, the entire tensioning roller needs to be replaced. During the maintenance process, the entire tensioning roller assembly needs to be lifted out of the elevator shell, and the bearing seat, belt clamping plate and external connecting components also need to be removed. This operation not only takes time, but also requires 4-6 hours of single maintenance, 3-4 operating personnel, and is easy to cause collision damage to the bearing seat, belt clamping plate and other related components during disassembly, further increasing the maintenance cost; at the same time, the replacement of the entire roller will cause the equipment to be out of service for a long time, affecting the production efficiency.

[0006] 3. Energy consumption and performance defects: The traditional roller is a solid steel structure, which is heavy, and the weight of a single roller can reach 300-500 kg. The driving motor of the elevator needs to bear the load of the weight of the roller during operation, resulting in high energy consumption; in addition, the wear-resistant performance of the single Hadfield 400 steel wear-resistant strip is limited, and the service life is about 3-6 months, and the surface has no special texture design, which is easy to cause the belt to slip due to dust accumulation, further reducing the transmission efficiency.

[0007] Therefore, it is a key requirement to develop a tensioning roller device with good wear-resistant performance, convenient maintenance and low energy consumption to solve the problems of the prior art. SUMMARY

[0008] In view of the problems in the prior art, the application provides a split tensioning roller device of a belt bucket elevator to overcome the above technical problems existing in the prior art.

[0009] The technical scheme of the application is implemented as follows:

[0010] A split tensioning roller device of a belt bucket elevator comprises a main shaft, a wheel core and at least three groups of wear-resistant modules, wherein:

[0011] The wheel core is coaxially fixedly connected with the main shaft, and the wheel core is uniformly provided with mounting positions matched with the wear-resistant modules on the outer periphery.

[0012] The wear-resistant module comprises a connecting plate and a plurality of wear-resistant strips, the plurality of wear-resistant strips are fixed on the connecting plate in a length direction of the connecting plate, and the connecting plate is fixedly connected with the mounting positions through detachable connecting pieces.

[0013] Further, the wheel core adopts a honeycomb hollow structure.

[0014] Further, the wear-resistant strip comprises a base material and a wear-resistant layer, wherein the base material is Q355 steel, and the wear-resistant layer is a tungsten carbide alloy overlaying layer.

[0015] Further, the wear-resistant layer is provided with an asymmetric trapezoidal groove pattern, the left side wall of the groove section has an inclination angle alpha of 60 degrees, the right side wall has an inclination angle beta of 30 degrees, and the groove bottom is a circular arc transition.

[0016] Further, the asymmetric trapezoidal groove pattern is distributed in a 15-degree oblique direction along the circumferential direction of the wheel core.

[0017] Further, the connecting plate is an arc structure, the arc of the connecting plate is matched with the outer diameter of the wheel core, and the connecting plate is provided with a positioning groove welded with the wear-resistant strip and a bolt hole connected with the mounting position.

[0018] Further, the detachable connecting piece is a high-strength bolt.

[0019] Further, each group of wear-resistant modules comprises one connecting plate and eight wear-resistant strips, and the eight wear-resistant strips are arranged in an equidistant ring shape on the outer periphery of the connecting plate.

[0020] The application has the following beneficial effects:

[0021] The application fundamentally solves the core pain points of traditional tensioning rollers in high-dust and high-wear working conditions through structural innovation and material optimization, and provides key protection for the stable operation of the elevator. In the performance improvement dimension, the device breaks through the limitation of traditional single material and adopts a gradient structure design of the base material and the wear-resistant layer to form a wear-resistant strip. The high toughness of the base material can effectively resist the impact of ash and slag, preventing the wear-resistant strip from breaking. The high-hardness wear-resistant layer on the surface can significantly enhance the wear resistance and prolong the service life of the wear-resistant strip, reducing equipment failures caused by wear-resistant strip failure. At the same time, the asymmetric trapezoidal groove pattern on the surface of the wear-resistant strip is designed through special angle design and trend planning, which not only solves the problem of dust accumulation and prevents imbalance of belt transmission caused by dust accumulation, but also ensures stable friction force between the belt and the roller, avoiding belt slip, further improving the stability and reliability of the elevator operation. In addition, the honeycomb hollow structure of the wheel core and the lightweight material selection greatly reduce the weight of the wheel core under the premise of ensuring the structural strength to meet the bearing demand, reduce the load of the elevator drive motor, help the equipment to realize low-energy-consumption operation, and meet the green production concept.

[0022] In addition, the split modular design of the application completely changes the traditional maintenance mode of disassembling the whole roller. When the wear-resistant strip needs to be replaced due to wear, it is not necessary to disassemble the external components such as the elevator bearing seat and the belt clamping plate, nor is it necessary to lift out the whole roller from the shell. Only simple operation inside the elevator box body can complete the replacement of a single or multiple wear-resistant modules, greatly simplifying the maintenance process, shortening the equipment downtime, and reducing the impact on production progress. At the same time, only the worn wear-resistant module needs to be replaced during maintenance, and the core components such as the wheel core and the main shaft can be reused for a long time without serious damage, avoiding the waste of components caused by traditional whole replacement, significantly reducing the maintenance cost and spare parts consumption of the whole life cycle of the equipment, saving a lot of operation and maintenance expenses for enterprises, and having high practical value and promotion significance. BRIEF DESCRIPTION OF DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments. Obviously, the drawings in the following description only some embodiments of the application, and for those skilled in the art, other drawings can be obtained without creative labor on the basis of these drawings.

[0024] Figure 1 is a structural schematic diagram of a split tensioning drum device of a conveyor belt bucket elevator according to an embodiment of the application;

[0025] Figure 2 is an assembly schematic diagram of a connecting plate of a split tensioning drum device of a conveyor belt bucket elevator according to an embodiment of the application;

[0026] Figure 3This is a schematic diagram of the connecting plate assembly of a split tensioning roller device for a conveyor belt bucket elevator according to an embodiment of the present invention;

[0027] Figure 4 This is a schematic diagram of the wear-resistant strip of a split tensioning roller device for a conveyor belt bucket elevator according to an embodiment of the present invention;

[0028] Figure 5 This is a schematic diagram of the asymmetric trapezoidal groove pattern of a split tensioning roller device for a conveyor belt bucket elevator according to an embodiment of the present invention;

[0029] Figure 6 This is a schematic diagram of the groove cross-section of an asymmetric trapezoidal groove pattern in a split tensioning roller device for a conveyor belt bucket elevator according to an embodiment of the present invention.

[0030] In the picture:

[0031] 1. Main shaft; 2. Wheel core; 3. Connecting plate; 4. Wear-resistant strip;

[0032] 41. Substrate; 42. Wear-resistant layer; 43. Asymmetric trapezoidal groove pattern. Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0034] According to an embodiment of the present invention, a split tensioning roller device for a conveyor belt bucket elevator is provided.

[0035] like Figures 1-6 As shown, the conveyor belt bucket elevator split tensioning roller device according to an embodiment of the present invention includes: a main shaft 1, a wheel core 2, and at least three sets of wear-resistant modules, wherein;

[0036] The wheel core 2 is coaxially and fixedly connected to the main shaft 1, and the outer circumference of the wheel core 2 is evenly provided with mounting positions that match the wear-resistant modules;

[0037] Any set of wear-resistant modules includes: a set of connecting plates 3 and eight wear-resistant strips 4. The eight wear-resistant strips 4 are fixed at intervals on the connecting plates 3 along the length direction of the connecting plates 3. The connecting plates 3 are fixedly connected to the mounting position through detachable connectors.

[0038] The main shaft 1 serves as the rotation center of the roller, with both ends connected to the bearing seats of the hoist, providing support and rotational power transmission for the roller as a whole. The wheel core 2 is coaxially fixedly connected to the main shaft 1, providing a basic frame for the installation of the wear-resistant strip 4. The wheel core 2 can adopt a honeycomb hollow structure with regular hexagonal honeycomb holes, which account for 35%-40% of the volume of the wheel core 2. The wheel core 2 is made of high-strength aluminum alloy or glass fiber reinforced plastic, with the high-strength aluminum alloy being model 6061-T6, which has a tensile strength ≥276MPa and a yield strength ≥207MPa. While ensuring strength, the weight is reduced, thus reducing the load on the hoist drive motor and lowering energy consumption.

[0039] In addition, three sets of connecting plate 3 mounting positions are evenly arranged on the outer periphery of the wheel core 2; the connecting plate 3 can be laser-cut from Q235 steel, and each set of connecting plate 3 has an arc structure with an arc matching the outer diameter of the wheel core 2. The connecting plate 3 has a pre-set positioning groove for welding with the wear-resistant strip 4 and bolt holes for connecting with the wheel core 2; each set of connecting plate 3 is fixed with eight wear-resistant strips 4, forming a wear-resistant module of one set of connecting plate 3 and eight wear-resistant strips 4.

[0040] In addition, such as Figures 4-5 As shown, the wear-resistant strip 4 employs a double-layer gradient structure of a base material 41 and a wear-resistant layer 42, solving the problem that traditional single-material wear-resistant strips are either brittle or tough but not wear-resistant. Specifically, the base material 41 can be made of Q355 steel with a yield strength ≥355MPa and an elongation ≥21%, possessing excellent toughness and impact resistance, preventing the wear-resistant strip 4 from breaking when impacted by ash and slag. The wear-resistant layer 42 is formed by plasma welding of tungsten carbide alloy onto the surface of the base material 41 using a WC content ≥90%, with a weld thickness of 3-5mm. After welding, the hardness of the wear-resistant layer 42 can reach 60-65HRC, significantly improving wear resistance compared to traditional Harda 400 steel, and extending its service life to 12-18 months.

[0041] Among them, such as Figure 6 As shown, asymmetrical trapezoidal groove patterns 43 are machined on the surface of the wear-resistant layer 42. Through structural parameter optimization, a balance of three functions—anti-dust accumulation, efficient dust removal, and anti-belt slippage—is achieved. Specifically:

[0042] Regarding the cross-sectional shape of the groove, the inclination angle α of the left side wall, i.e. the front wall along the belt running direction, is 60°, and the inclination angle β of the right side wall, i.e. the rear wall, is 30°. The bottom of the groove adopts a circular arc transition with a radius R = 2mm. The 60° front wall can use the inertial force of dust to make the dust slide down the steep slope and reduce the amount of dust remaining. The 30° rear wall can increase the meshing depth between the belt and the pattern, improve the anti-slip friction, and increase the friction by 15%-20% compared with the traditional rectangular pattern. The circular arc bottom of the groove can prevent dust from accumulating and agglomerating at right angles.

[0043] In addition, during implementation, the groove depth is 3-5mm, half the depth of traditional rectangular grooves, and the groove spacing is 15-20mm, 50% wider than traditional rectangular grooves. The shallow depth reduces the depth of dust embedding in the grooves, lowering the probability of agglomeration; the wide spacing increases the ash discharge channel, and even if a small amount of dust agglomerates, it can be dislodged by the inherent vibration of the elevator during operation, with a vibration frequency of 2-5Hz. At the same time, the groove direction can be distributed at a 15° angle along the circumference of the roller; the angled grooves create an angle between the dust discharge direction and the belt running direction, using the centrifugal force generated by the roller rotation to assist the dust in being thrown outwards, significantly improving the ash discharge efficiency compared to traditional parallel circumferential grooves.

[0044] Using the above method, the main shaft 1 is pre-inserted into the inner hole of the wheel core 2, using an interference fit connection. Anaerobic adhesive is applied to the mating surface to enhance the connection stability. After assembly, the coaxiality of the wheel core 2 and the main shaft 1 is checked using a dial indicator to ensure that the coaxiality error is ≤0.05mm. Eight wear-resistant strips 4 in each group are placed in the positioning groove of the connecting plate 3, and the wear-resistant strips 4 are welded to the connecting plate 3 using carbon dioxide gas shielded welding. After welding, the weld is ground to avoid weld protrusions affecting belt operation. After each group of welding is completed, the flatness of the wear-resistant strips 4 is checked to ensure that the flatness error is ≤0.2mm. The three sets of connecting plates 3 and the corresponding wear-resistant modules of the wear-resistant strips 4 are installed on the mounting positions on the outer periphery of the wheel core 2 and fixed with M12×30 high-strength bolts. The bolt tightening torque is set to 55-60 N·m. After assembly, the wheel core 2 is rotated to check for any jamming on the surface of the wear-resistant strips 4 to ensure that the roller rotates smoothly.

[0045] In addition, during routine maintenance using a thickness gauge, when the wear-resistant strip 4 wears down to a thickness of ≤3mm, it should be repaired or replaced. The specific steps are as follows:

[0046] Stop the machine and disconnect the power supply to the hoist; rotate wheel core 2 so that the connecting plate 3 and wear-resistant strip 4 to be replaced, i.e., the corresponding wear-resistant module, are rotated to the front, i.e., in the middle position of the upper and lower belts; use a wrench to remove the high-strength bolts on the connecting plate 3, and pull the connecting plate 3 and wear-resistant strip 4 as a whole out of the wheel core 2; install the new connecting plate 3 and wear-resistant strip 4 wear-resistant module into the mounting position on the wheel core 2, and tighten the bolts. Repeat the above steps to replace one or three sets of wear-resistant modules according to the wear condition of the wear-resistant strip 4; after replacement, close the maintenance door, start the hoist for no-load test run, and put it into normal use after confirming normal operation.

[0047] In summary, by utilizing the above-described technical solution of the present invention, the following effects can be achieved:

[0048] This invention, through structural innovation and material optimization, fundamentally solves the core pain point of traditional tensioning rollers under high dust and high wear conditions, providing a key guarantee for the stable operation of the hoist. In terms of performance improvement, the device breaks through the limitations of traditional single materials, employing a gradient structure design of the wear-resistant strip 4 with a base material 41 and a wear-resistant layer 42. The high toughness of the base material 41 effectively resists the impact of ash and slag, preventing the wear-resistant strip 4 from breaking, while the high-hardness wear-resistant layer 42 significantly enhances wear resistance, substantially extending the service life of the wear-resistant strip 4 and reducing equipment failures caused by its failure. Simultaneously, the asymmetric trapezoidal groove pattern 43 on the surface of the wear-resistant strip 4, through a special angle design and orientation planning, not only solves the problem of dust accumulation and prevents belt drive imbalance caused by dust accumulation, but also ensures stable friction between the belt and the roller, preventing belt slippage and further improving the stability and reliability of the hoist operation. In addition, the honeycomb hollow structure and lightweight material selection of the wheel core 2 significantly reduce its own weight while ensuring that the structural strength meets the load-bearing requirements, thereby reducing the load on the hoist drive motor and helping the equipment to achieve low-energy operation, which is in line with the concept of green production.

[0049] Furthermore, the modular design of this invention completely changes the traditional maintenance mode of disassembling the entire roller. When the wear-resistant strip 4 wears and needs to be replaced, there is no need to remove external components such as the hoist bearing seat and belt clamp, nor is it necessary to lift the entire roller out of the housing. The replacement of one or more sets of wear-resistant modules can be completed simply by operating inside the hoist housing, which greatly simplifies the maintenance process, shortens equipment downtime, and reduces the impact on production schedule. At the same time, during the maintenance process, only the worn wear-resistant modules need to be replaced. Core components such as the wheel core 2 and main shaft 1 can be reused for a long time if there is no serious damage, avoiding the waste of parts caused by traditional whole replacement. This significantly reduces the maintenance cost and spare parts consumption throughout the equipment's life cycle, saving enterprises a lot of operation and maintenance expenses, and has extremely high practical value and promotion significance.

[0050] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Those skilled in the art, upon considering the disclosure in the specification and embodiments, will readily conceive of other embodiments of this disclosure. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and embodiments are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the claims.

[0051] It should be understood that this disclosure is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this disclosure is limited only by the appended claims.

Claims

1. A split tensioning roller device for a conveyor belt bucket elevator, characterized in that, include: The main shaft (1), the wheel core (2), and at least three sets of wear-resistant modules, wherein; The wheel core (2) is coaxially and fixedly connected to the main shaft (1), and the outer circumference of the wheel core (2) is uniformly provided with mounting positions that match the wear-resistant module; The wear-resistant module includes a connecting plate (3) and several wear-resistant strips (4). The several wear-resistant strips (4) are fixed at intervals on the connecting plate (3) along the length direction of the connecting plate (3). The connecting plate (3) is fixedly connected to the mounting position through a detachable connector.

2. The split tensioning roller device for a conveyor belt bucket elevator according to claim 1, characterized in that, The wheel core (2) adopts a honeycomb hollow structure.

3. The split tensioning roller device for a conveyor belt bucket elevator according to claim 1, characterized in that, The wear-resistant strip (4) includes a substrate (41) and a wear-resistant layer (42), wherein the substrate (41) is Q355 steel and the wear-resistant layer (42) is a tungsten carbide alloy weld overlay.

4. The split tensioning roller device for a conveyor belt bucket elevator according to claim 3, characterized in that, The wear-resistant layer (42) has an asymmetrical trapezoidal groove pattern (43) on its surface. The inclination angle α of one side wall of the groove cross section is 60°, the inclination angle β of the other side wall is 30°, and the bottom of the groove is a rounded transition.

5. The split tensioning roller device for a conveyor belt bucket elevator according to claim 4, characterized in that, The asymmetric trapezoidal groove pattern (43) is distributed obliquely at 15° along the circumference of the wheel core (2).

6. The split tensioning roller device for a conveyor belt bucket elevator according to claim 1, characterized in that, The connecting plate (3) has an arc-shaped structure. The arc of the connecting plate (3) matches the outer diameter of the wheel core (2). The connecting plate (3) is provided with a positioning groove for welding to the wear-resistant strip (4) and bolt holes for connecting to the mounting position.

7. The split tensioning roller device for a conveyor belt bucket elevator according to claim 6, characterized in that, The detachable connector is a high-strength bolt.

8. The split tensioning roller device for a conveyor belt bucket elevator according to claim 7 or 1, characterized in that, Each set of wear-resistant modules includes: a set of connecting plates (3) and eight wear-resistant strips (4), the eight wear-resistant strips (4) being arranged in a ring at equal intervals around the outer periphery of the connecting plates (3).

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