A device and method for quick replacement of a belt idler

Abstract

The present application relates to the technical field of conveying equipment maintenance, and particularly relates to a device and method for quickly replacing a belt supporting roller. The device comprises a base, a lower supporting rod, a supporting cylinder, an upper supporting rod and a rotating auxiliary rod. The lower supporting rod is vertically fixed to the base. The supporting cylinder is threadedly connected to the lower supporting rod and the upper supporting rod. The upper supporting rod is provided with a belt supporting frame with a protective pad at the upper end. The base is a multi-supporting-plate integrated structure. An auxiliary support is arranged between the lower supporting rod and the base. The sidewall of the supporting cylinder is provided with a hole for inserting the rotating auxiliary rod. The method comprises the following steps: lifting the belt by using the device, disassembling the old supporting roller, installing a new supporting roller, resetting the device, removing the device, and performing a stop and locking safety operation before operation. The belt is stably lifted and falls by screw transmission, without manual lifting and prying, which significantly improves the operation safety, reduces the labor intensity and shortens the replacement time.

Description

Technical Field

[0001] This invention relates to the field of conveyor equipment maintenance technology, and in particular to a device and method for quickly replacing belt idlers. Background Technology

[0002] Blast furnace belt conveyors are crucial continuous material conveying equipment in modern blast furnace production, and their stable operation directly affects the blast furnace condition and production indicators. Idler rollers, as key support components of belt conveyors, are numerous and constantly bear loads, wear, and environmental corrosion, making them vulnerable parts. Regular or emergency replacement of damaged idler rollers is essential maintenance to ensure the normal operation of the conveyor line.

[0003] Currently, the conventional method for replacing belt idlers in the industry mainly relies on manual operation. The typical steps are as follows: First, the entire line or part of the machine is stopped. The operator uses tools such as pry bars and manual hoists to separate the belt from the damaged idler in the narrow space under the belt by manually lifting and prying. Then, the fasteners (such as snap rings and bolts) of the old idler are removed and taken off the bracket. The new idler is then moved to the installation position and re-fixed to the bearing seat.

[0004] Traditional idler replacement processes have several significant drawbacks. First, they are labor-intensive and pose high safety risks: due to limited operating space and the large weight of the idlers, manual handling, positioning, and installation are extremely laborious. If new idlers cannot be replaced quickly, muscle strain is likely to result. When prying the belt or lifting heavy objects, there is a high risk of tools slipping or heavy objects falling and injuring personnel, especially when working on slopes or high-altitude corridors, where the danger is further increased. Second, replacement efficiency is low and downtime losses are significant: traditional replacement processes are cumbersome, rely on multiple people working together, and are time-consuming. Especially for long-distance, high-speed conveyors, for safety reasons, the entire line often needs to be shut down. The downtime caused by each replacement directly affects the stable operation of the blast furnace, resulting in huge economic losses. Third, there is potential damage to equipment and belts: using tools such as pry bars to forcibly separate the belt from the idlers, or disassembling and assembling under improper force, can easily scratch the belt surface or damage the idler bracket (12) and adjacent components, creating potential faults for subsequent operation.

[0005] To address the above problems, a new method for replacing belt idlers has been invented. This method significantly shortens the replacement time, effectively reduces labor intensity and safety risks, and is highly efficient. It does not affect continuous blast furnace production and does not cause potential damage to equipment and belts. It is a method that fundamentally revolutionizes the work process and achieves safe, efficient, and labor-saving belt idler replacement. Summary of the Invention

[0006] To address the technical problems of low efficiency and high risk caused by manual replacement of belt idlers in existing technologies, this invention provides a device and method for quickly replacing belt idlers.

[0007] Therefore, the present invention provides the following technical solution:

[0008] A device for quickly changing belt idlers includes a base, a lower support rod, a support cylinder, and an upper support rod. The lower support rod is vertically fixed on the base. The upper end of the lower support rod is provided with a lower threaded section. The lower part of the support cylinder is threadedly engaged with the lower threaded section. The lower end of the upper support rod is provided with an upper threaded section. The upper threaded section is threadedly engaged with the upper end of the support cylinder (forming a spiral lifting mechanism to achieve smooth and labor-saving belt lifting and ensure controllable lifting height).

[0009] Furthermore, the base includes a first support plate, a second support plate, and a third support plate; the lower support rod is fixedly installed on the first support plate, and two second support plates are integrally formed on both sides of the first support plate, and the two second support plates are arranged vertically and parallel to each other; the first support plate is located at the lower end of the two second support plates, and the upper end of the two second support plates is integrally formed with a third support plate in opposite directions (so that the base can be stably placed on the roller bracket, improving the stability and versatility of the device when it is placed, and making it less prone to tipping over or sliding).

[0010] Furthermore, a belt support frame is fixedly installed at the upper end of the upper support rod.

[0011] Furthermore, a protective pad is fixedly installed on the upper surface of the belt support frame (to prevent scratches or wear on the belt surface during the lifting process and to protect the integrity of the belt).

[0012] Furthermore, the side wall of the support cylinder is provided with an insertion hole, into which a rotating auxiliary rod is inserted (to facilitate the operator to drive the support cylinder to rotate with minimal effort, achieving rapid lifting and lowering, making the operation simple and efficient).

[0013] Furthermore, an auxiliary bracket is fixedly connected between the lower support rod and the base.

[0014] A method for quickly changing belt idlers, using the aforementioned device for quickly changing belt idlers, the method comprising the following steps: S1. Place the base of the device on the adjacent idler bracket of the idler to be replaced, ensuring that the two third support plates of the base are placed on the adjacent idler brackets accordingly; S2. Insert the rotating auxiliary rod into the insertion hole on the side wall of the support cylinder, rotate the rotating auxiliary rod to drive the support cylinder to rotate, and use the threaded engagement between the support cylinder and the lower support rod and the upper support rod to drive the upper support rod and the belt support frame at the upper end to rise, so that the belt is completely separated from the idler roller to be replaced, and then stop rotating the rotating auxiliary rod. S3. Remove the old idler roller to be replaced axially from the bearing housing of its bracket; S4. Place the new idler into the bearing housing of the idler bracket, ensuring that the new idler is installed in place and can rotate freely; S5. Reverse rotation of the auxiliary rod drives the support cylinder to rotate in the opposite direction, causing the upper support rod and belt support frame to descend, so that the belt falls onto the surface of the new idler roller; S6. Remove the rotating auxiliary rod from the insertion hole of the support cylinder and remove the device from the idler roller bracket to complete the idler roller replacement.

[0015] Furthermore, before step S1, the system also includes performing a shutdown and locking / tagout safety operation on the belt conveyor.

[0016] Advantages and positive effects of the present invention: This invention achieves mechanical lifting and support of the belt through a spiral lifting mechanism, eliminating the need for operators to perform dangerous operations such as manual lifting and prying under the belt. This effectively avoids safety risks caused by falling heavy objects and accidental equipment startup, and significantly improves the safety of maintenance operations.

[0017] The device of this invention, combined with a standardized operating procedure, eliminates the need for multiple people to work together to disassemble and assemble the idler rollers. The single replacement process is simple and quick, significantly shortening maintenance time and minimizing production line downtime losses caused by maintenance. It can meet the needs of online rapid replacement.

[0018] The base adopts a multi-support plate integrated structure, which can be stably placed on the roller bracket. It is compatible with belt conveyors of different specifications and layouts. It has high overall strength and stable support, and can be used stably in confined spaces and complex working conditions.

[0019] Effortless lifting can be achieved by rotating the auxiliary rod. The operation is simple and intuitive, requiring low skill and physical strength from the operator. Ordinary maintenance personnel can complete the operation independently after simple training, reducing labor costs and operational difficulty. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 A front view of a device for quickly changing belt rollers provided by the present invention.

[0022] Figure 2 A side view of a device for quickly changing belt rollers provided by the present invention.

[0023] Figure 3 This is a top view of a device for quickly changing belt rollers provided by the present invention.

[0024] In the diagram: 1. Lower support rod; 2. Support cylinder; 3. Upper support rod; 4. Lower threaded section; 5. Upper threaded section; 6. First support plate; 7. Second support plate; 8. Third support plate; 9. Belt support frame; 10. Rotation auxiliary rod; 11. Auxiliary bracket; 12. Idler roller bracket. Detailed Implementation

[0025] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0026] This invention provides a device for quickly replacing belt idlers, such as... Figure 1-3 As shown, it includes a base, a lower support rod 1, a support cylinder 2, and an upper support rod 3.

[0027] The base includes a first support plate 6, a second support plate 7, and a third support plate 8; the lower support rod 1 is fixedly installed on the first support plate 6, and the two second support plates 7 are integrally formed on both sides of the first support plate 6, and the two second support plates 7 are arranged vertically and parallel to each other; the first support plate 6 is located at the lower end of the two second support plates 7, and the upper end of the two second support plates 7 is integrally formed with the third support plate 8 in opposite directions.

[0028] The lower support rod 1 is vertically fixed on the first support plate 6, and an auxiliary bracket 11 is also fixedly connected between the lower support rod 1 and the base. The upper end of the lower support rod 1 is provided with a lower threaded section 4, and the lower part of the support cylinder 2 is threadedly engaged with the lower threaded section 4. The lower end of the upper support rod 3 is provided with an upper threaded section 5, and the upper threaded section 5 is threadedly engaged with the upper end of the support cylinder 2.

[0029] A belt support frame 9 is fixedly installed at the upper end of the upper support rod 3. A protective pad is fixedly installed on the upper surface of the belt support frame 9.

[0030] The side wall of the support cylinder 2 is provided with an insertion hole, and a rotating auxiliary rod 10 is inserted into the insertion hole.

[0031] A method for quickly changing belt idlers, using the aforementioned device for quickly changing belt idlers, the method comprising the following steps: S1. Perform a shutdown and lockout safety operation on the belt conveyor, place the base of the device on the idler bracket 12 adjacent to the idler to be replaced, and ensure that the two third support plates 8 of the base are placed on the adjacent idler bracket 12.

[0032] S2. Insert the rotating auxiliary rod 10 into the insertion hole on the side wall of the support cylinder 2, rotate the rotating auxiliary rod 10 to drive the support cylinder 2 to rotate, and use the threaded engagement between the support cylinder 2 and the lower support rod 1 and the upper support rod 3 to drive the upper support rod 3 and the belt support frame 9 at the upper end to rise, so that the belt is completely separated from the idler roller to be replaced, and then stop rotating the rotating auxiliary rod 10.

[0033] S3. Remove the old idler roller to be replaced axially from the bearing housing of its support.

[0034] S4. Place the new idler into the bearing housing of the idler bracket 12, ensuring that the new idler is installed in place and rotates flexibly.

[0035] S5. Reverse rotation of the auxiliary rod 10 drives the support cylinder 2 to rotate in the opposite direction, causing the upper support rod 3 and the belt support frame 9 to descend, so that the belt falls onto the surface of the new idler roller.

[0036] S6. Remove the rotating auxiliary rod 10 from the insertion hole of the support cylinder 2 and remove the device from the idler roller bracket 12 to complete the idler roller replacement.

[0037] Working principle: By inserting the rotating auxiliary rod into the insertion hole of the support cylinder, rotating the auxiliary rod drives the support cylinder to rotate. The threaded engagement between the support cylinder and the lower and upper support rods converts the rotational motion into linear lifting motion. When the auxiliary rod is rotated clockwise, the support cylinder drives the upper support rod and belt support frame to rise synchronously, smoothly lifting the belt and completely unloading the idler to be replaced, facilitating the removal of the old idler and subsequent installation of the new idler. When the auxiliary rod is rotated counterclockwise, the support cylinder rotates in the opposite direction, slowly lowering the upper support rod and belt support frame, allowing the belt to smoothly fall onto the surface of the new idler, completing the replacement.

[0038] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A device for quickly changing belt idlers, characterized in that, It includes a base, a lower support rod (1), a support cylinder (2) and an upper support rod (3). The lower support rod (1) is vertically fixed on the base. The upper end of the lower support rod (1) is provided with a lower threaded section (4). The lower part of the support cylinder (2) is threaded with the lower threaded section (4). The lower end of the upper support rod (3) is provided with an upper threaded section (5). The upper threaded section (5) is threaded with the upper end of the support cylinder (2).

2. The device for quickly changing belt idlers according to claim 1, characterized in that, The base includes a first support plate (6), a second support plate (7), and a third support plate (8); the lower support rod (1) is fixedly installed on the first support plate (6), and the two second support plates (7) are integrally formed on both sides of the first support plate (6), and the two second support plates (7) are arranged vertically and parallel to each other; the first support plate (6) is located at the lower end of the two second support plates (7), and the upper ends of the two second support plates (7) are integrally formed with the third support plate (8) in opposite directions.

3. The device for quickly changing belt idlers according to claim 1, characterized in that, A belt support frame (9) is fixedly installed at the upper end of the upper support rod (3).

4. The device for quickly changing belt idlers according to claim 3, characterized in that, A protective pad is fixedly installed on the upper surface of the belt support frame (9).

5. The device for quickly changing belt idlers according to claim 1, characterized in that, The side wall of the support cylinder (2) is provided with an insertion hole, and a rotating auxiliary rod (10) is inserted into the insertion hole.

6. The device for quickly changing belt idlers according to claim 1, characterized in that, An auxiliary bracket (11) is also fixedly connected between the lower support rod (1) and the base.

7. A method for quickly replacing belt idlers, characterized in that, The method of using the quick-change belt idler apparatus according to any one of claims 1-6 includes the following steps: S1. Place the base of the device on the adjacent idler bracket (12) of the idler to be replaced, ensuring that the two third support plates (8) of the base are placed on the adjacent idler bracket (12); S2. Insert the rotating auxiliary rod (10) into the insertion hole on the side wall of the support cylinder (2), rotate the rotating auxiliary rod (10) to drive the support cylinder (2) to rotate, and use the threaded connection between the support cylinder (2) and the lower support rod (1) and the upper support rod (3) to drive the upper support rod (3) and the belt support frame (9) at the upper end to rise, so that the belt is completely separated from the idler roller to be replaced, and then stop rotating the rotating auxiliary rod (10). S3. Remove the old idler roller to be replaced axially from the bearing housing of its bracket; S4. Place the new idler into the bearing seat of the idler bracket (12) to ensure that the new idler is installed in place and rotates flexibly; S5. Reverse rotation of the auxiliary rod (10) drives the support cylinder (2) to rotate in the opposite direction, causing the upper support rod (3) and belt support frame (9) to descend, so that the belt falls onto the surface of the new idler roller; S6. Remove the rotating auxiliary rod (10) from the insertion hole of the support cylinder (2) and remove the device from the roller bracket (12) to complete the roller replacement.

8. A method for quickly replacing belt idlers according to claim 7, characterized in that, Before step S1, the system also includes stopping the belt conveyor and locking and tagging it for safety.

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