A roller arrangement, a method of mounting and a method of lubricating

Abstract

The application discloses a roller device, a mounting method and a lubricating method. The roller device comprises two end covers, a roller assembly and a number of plugging pieces same as the number of powder adding holes. The end cover is provided with a powder adding hole, and the end cover is annular, and the middle part of the end cover is provided with a through hole. The roller assembly comprises a roller body, a roller inner sleeve, a roller shaft sleeve and a screw shaft arranged coaxially. The roller body and the roller inner sleeve are arranged at intervals to form a containing cavity communicated with the powder adding hole. The roller inner sleeve is provided with a plurality of first through holes communicated with the containing cavity along the circumference of the roller inner sleeve. The roller inner sleeve and the roller shaft sleeve are arranged at intervals to form a first lubricating passage communicated with the first through hole. The roller shaft sleeve is provided with a plurality of second through holes communicated with the first lubricating passage along the circumference of the roller shaft sleeve. The two ends of the roller inner sleeve are respectively welded with the two end covers. The two ends of the roller body are respectively welded with the two end covers. The number of plugging pieces is same as the number of powder adding holes. The service life and the operation stability of the roller device are improved.

Description

Technical Field

[0001] This application belongs to the field of coke oven production technology, specifically relating to a roller device, installation method, and lubrication method. Background Technology

[0002] Dry quenching technology is an important supporting process for coke oven production. In the dry quenching process, a loading chute is used to transfer red-hot coke from the coke can to the dry quenching furnace. The top of the loading chute is equipped with a dust cover, on which a roller device is installed to support and guide the movement of the loading chute. However, during dry quenching, the rollers on top of the loading chute cover face harsh working conditions. On the one hand, the reciprocating movement of the coke can exert a strong impact load on the rollers on top of the cover; on the other hand, the rollers operate in a high-temperature environment for extended periods, and the dust generated by flying coke powder also exacerbates wear on the rollers. Under these extreme conditions, traditional lubrication methods are ineffective; therefore, most rollers are not designed with lubrication, relying solely on dry friction transmission between the roller body and the screw shaft.

[0003] Existing dust cover roller devices mainly consist of a roller body, a roller bushing, and a screw shaft. The screw shaft passes through the roller bushing, and the two achieve transmission through a clearance fit. In actual operation, dry friction contact exists between the roller body and the roller bushing, and between the roller bushing and the screw shaft, lacking effective lubrication and dust protection measures. Under prolonged high-load operation and high-temperature dust environments, dry friction transmission leads to severe wear on the mating surfaces of the roller body, roller bushing, and screw shaft. This causes premature wear and damage to the rollers, shortening their service life, increasing equipment maintenance costs and downtime, and seriously affecting the stability and economy of dry quenching coke production. Summary of the Invention

[0004] To address the technical problems of wear and high maintenance costs in current idler roller devices, this application provides an idler roller device, an installation method, and a lubrication method.

[0005] In a first aspect of this application, a roller device is provided, comprising: Two end caps, each end cap having a powder filling hole, the end caps being annular in shape, and having a through hole in the middle of the end cap; An idler roller assembly includes an idler roller body, an idler roller inner sleeve, an idler roller bushing, and a screw shaft coaxially arranged. The idler roller body and the idler roller inner sleeve are spaced apart to form a receiving cavity communicating with a powder filling hole. The idler roller inner sleeve has a plurality of first through holes communicating with the receiving cavity along its circumference. The idler roller inner sleeve and the idler roller bushing are spaced apart to form a first lubrication passage communicating with the first through holes. The idler roller bushing has a plurality of second through holes communicating with the first lubrication passage along its circumference. The idler roller bushing and the screw shaft are spaced apart to form a second lubrication passage communicating with the second through holes. Both ends of the idler roller inner sleeve are welded to two end caps, and both ends of the idler roller body are welded to two end caps, respectively. The idler roller bushing and the screw shaft both pass through the through holes of the end caps, and the screw shaft passes through the idler roller bushing, and the screw shaft is used to connect to an idler roller seat. A number of sealing components, the same as the number of powder filling holes, are provided at the powder filling holes.

[0006] In some embodiments, the inner diameter of the through hole of the end cap is larger than the outer diameter of the idler roller bushing; The inner diameter of the inner sleeve of the idler roller is larger than the outer diameter of the outer sleeve of the idler roller shaft. The distance between the inner sleeve of the idler roller and the bushing of the idler roller is 1mm to 2mm.

[0007] In some embodiments, the inner diameter of the idler roller bushing is larger than the outer diameter of the screw shaft; The distance between the idler roller bushing and the screw shaft is 0.4mm~0.6mm.

[0008] In some embodiments, each of the end caps is provided with a powder filling hole; The inner diameter of the powder feeding hole is larger than the inner diameter of the first through hole; The inner diameter of the first through hole is larger than the inner diameter of the second through hole.

[0009] In some embodiments, the inner diameter of the powder feeding hole is 14mm to 16mm; The inner diameter of the first through hole is 4mm~6mm; The inner diameter of the second through hole is 2.5mm~3.5mm.

[0010] In some embodiments, the first through hole is a straight through hole, and the second through hole is an angled through hole.

[0011] In some embodiments, the sealing element is a threaded element, and the inner wall of the powder filling hole is provided with an internal thread that mates with the threaded element.

[0012] In a second aspect of this application, an installation method based on the above-described idler roller device is provided, comprising the following steps: The idler body and the idler inner sleeve are welded to the two end caps; The roller bushing is inserted into the inner sleeve of the roller along the axial direction. The screw shaft is inserted into the idler roller bushing along the axial direction, and the shaft end of the screw shaft is connected to the idler roller seat. Lubricating medium is injected into the powder filling hole of the end cap, so that the lubricating medium flows into the second lubrication passage through the powder filling hole, the receiving cavity, the first through hole, the first lubrication passage, and the second through hole. After the injection is completed, the powder filling hole is sealed by the sealing member.

[0013] In a second aspect of this application, a lubrication method for a roller device based on any of the above-described embodiments is provided, comprising the following steps: The sealing member is removed from the powder filling hole, and the lubricating medium is injected from the powder filling hole. The lubricating medium flows into the second lubricating passage through the receiving cavity, the first through hole, the first lubrication passage, and the second through hole in sequence to lubricate the mating surface between the idler roller bushing and the screw shaft. After injection is completed, the powder injection hole is sealed by the sealing component; Repeat the above steps periodically.

[0014] In some embodiments, the lubricating medium is coke powder, and the particle size of the lubricating medium is 1 mm to 3 mm.

[0015] A roller device, installation method, and lubrication method are provided according to one or more embodiments of this application. The roller device includes two end caps, a roller assembly, and sealing members equal in number to the powder filling holes. The end caps are provided with powder filling holes, are annular, and have through holes in their center. The roller assembly includes a roller body, an inner roller sleeve, a roller bushing, and a screw shaft coaxially arranged. The roller body and the inner roller sleeve are spaced apart to form a receiving cavity communicating with the powder filling holes. The inner roller sleeve has a plurality of first through holes communicating with the receiving cavity along its circumference, and the inner roller sleeve and the roller bushing are spaced apart to form a communication with the first through holes. The roller device comprises a first lubrication passage; a roller bushing with several second through holes communicating with the first lubrication passage along its circumference; the roller bushing and the screw shaft are spaced apart to form a second lubrication passage communicating with the second through holes; the two ends of the roller inner sleeve are welded to two end caps respectively; the two ends of the roller body are welded to two end caps respectively; both the roller bushing and the screw shaft pass through the through holes of the end caps, the screw shaft passes through the roller bushing, and the screw shaft is used to connect with the roller seat; and the same number of sealing parts as the powder filling holes are provided in the powder filling holes. The roller device of this application, through the design of a multi-stage lubrication passage, realizes the step-by-step guidance and conveying of the lubricating medium from the powder filling hole to the mating surface of the roller bushing and the screw shaft, solving the problem of difficult lubrication in existing roller devices and improving the service life and operational stability of the roller device. Attached Figure Description

[0016] Figure 1 A schematic diagram of the roller device in one or more embodiments of this application is shown.

[0017] Figure 2 It shows Figure 1 A flowchart of the installation method for the idler roller device.

[0018] Figure 3 It shows Figure 1 A flowchart of the lubrication method for the idler roller device.

[0019] Explanation of reference numerals in the attached drawings: 100-Idler assembly, 110-End cap, 111-Powder filling hole, 120-Idler assembly, 121-Idler body, 122-Idler inner sleeve, 123-Idler bushing, 124-Screw shaft, 125-First through hole, 126-Second through hole, 130-Sealing component, 140-Lubricating medium. Detailed Implementation

[0020] To enable those skilled in the art to more clearly understand this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0021] Please see Figure 1 According to a first aspect of this application, a roller device 100 is provided, including two end caps 110, a roller assembly 120, and a number of sealing members 130 equal to the number of powder filling holes 111. The end caps 110 are provided with powder filling holes 111, and are annular in shape with a through hole in the middle. The roller assembly 120 includes a roller body 121, an inner roller sleeve 122, a roller bushing 123, and a screw shaft 124 coaxially arranged. The roller body 121 and the inner roller sleeve 122 are spaced apart to form a receiving cavity communicating with the powder filling holes 111. The inner roller sleeve 122 is provided with a plurality of first through holes 125 communicating with the receiving cavity along the circumference of the inner roller sleeve 122. The inner roller sleeve 122 and the roller bushing 123 are spaced apart. A first lubrication passage is formed to communicate with the first through hole 125; the idler roller bushing 123 is provided with a plurality of second through holes 126 communicating with the first lubrication passage along the circumference of the idler roller bushing 123; the idler roller bushing 123 and the screw shaft 124 are spaced apart to form a second lubrication passage communicating with the second through holes 126; the two ends of the idler roller inner sleeve 122 are respectively welded to two end caps 110; the two ends of the idler roller body 121 are respectively welded to two end caps 110; the idler roller bushing 123 and the screw shaft 124 are both inserted through the through holes of the end caps 110; the screw shaft 124 is inserted through the idler roller bushing 123 and is used to connect with the idler roller seat; the same number of sealing members 130 as the powder filling holes 111 are provided in the powder filling holes 111.

[0022] The end cap 110 has a through hole in its center for the idler roller sleeve 123 and the screw shaft 124 to pass through. The idler roller body 121 and the idler roller inner sleeve 122 are coaxially spaced, forming an annular receiving cavity between them. The receiving cavity is connected to the powder filling hole 111, facilitating the injection of lubricating medium 140 from the outside. The first lubrication passage is connected to the first through hole 125, allowing the lubricating medium 140 to enter the first lubrication passage from the receiving cavity. The second lubrication passage is connected to the second through hole 126, allowing the lubricating medium 140 to finally reach the mating surface of the screw shaft 124 and the idler roller sleeve 123. The two ends of the idler roller inner sleeve 122 are welded and fixed to the two end caps 110 respectively, ensuring the sealing and overall strength of the connection between the idler roller inner sleeve 122 and the end caps 110. The two ends of the idler roller body 121 are welded and fixed to the two end caps 110 respectively, further enhancing the overall structural stability of the idler roller device 100. Both the idler roller bushing 123 and the screw shaft 124 pass through the through hole of the end cover 110. The screw shaft 124 passes inside the idler roller bushing 123, and the shaft end of the screw shaft 124 is used to connect with the idler roller seat to realize the installation and fixation of the idler roller device 100. The number of sealing parts 130 is the same as the number of powder filling holes 111. The sealing parts 130 are set in the powder filling holes 111 to seal the powder filling holes 111 and prevent the lubricating medium 140 from leaking and external impurities from entering.

[0023] Therefore, the idler roller device 100 of this application, through the design of a multi-stage lubrication channel, realizes the step-by-step guidance and conveying of the lubricating medium 140 from the powder filling hole 111 to the mating surface of the idler roller bushing 123 and the screw shaft 124, which solves the problem of lubrication difficulties in the existing idler roller device 100 and improves the service life and operational stability of the idler roller device 100.

[0024] In some embodiments, the inner diameter of the through hole of the end cap 110 is larger than the outer diameter of the roller bushing 123; this ensures that the roller bushing 123 can be smoothly inserted into the through hole of the end cap 110, while a certain gap is formed between the end cap 110 and the roller bushing 123, which facilitates the installation, positioning and axial adjustment of the roller bushing 123.

[0025] In some embodiments, the inner diameter of the inner sleeve 122 is larger than the outer diameter of the outer sleeve 123; this ensures that the outer sleeve 123 can be inserted into the inner sleeve 122, thus achieving coaxial arrangement of the inner sleeve 122 and the outer sleeve 123, while facilitating relative rotation between the two.

[0026] In some embodiments, the distance between the inner sleeve 122 and the bushing 123 of the idler roller is 1mm to 2mm. The distance between the inner sleeve 122 and the bushing 123 can be 1mm, 1.5mm, or 2mm. This allows the lubricating medium 140 to form an effective lubrication channel between the inner sleeve 122 and the bushing 123, ensuring smooth flow of the lubricating medium 140 within the first lubrication channel. This avoids insufficient penetration of the lubricating medium 140 due to an excessively small gap. Simultaneously, the gap should not be too large to prevent the overall structure of the idler roller assembly 100 from becoming loose, ensuring operational accuracy. This dimensional design, while ensuring lubrication effectiveness, also considers the overall structural strength and ease of installation of the idler roller assembly 100, enabling the idler roller assembly 100 to maintain good lubrication and stable transmission performance even under high-load operating conditions.

[0027] In some embodiments, the inner diameter of the roller bushing 123 is larger than the outer diameter of the screw shaft 124, so that the screw shaft 124 can rotate flexibly within the roller bushing 123, while ensuring that the second lubrication passage can form an effective lubrication film.

[0028] In some embodiments, the distance between the idler roller bushing 123 and the screw shaft 124 is 0.4mm to 0.6mm. The distance between the idler roller bushing 123 and the screw shaft 124 can be 0.4mm, 0.45mm, 0.5mm, 0.55mm, or 0.6mm. Too small a distance will make it difficult for the lubricating medium 140 to enter, resulting in poor lubrication and potential rotational jamming; too large a distance will reduce the coaxiality between the idler roller bushing 123 and the screw shaft 124, decreasing operational accuracy and weakening the load-bearing capacity of the lubricating film. Therefore, the distance between the idler roller bushing 123 and the screw shaft 124 is 0.4mm to 0.6mm. This distance range allows the lubricating medium 140 to form a uniform lubricating film between the screw shaft 124 and the idler roller bushing 123, reducing wear caused by direct metal-to-metal contact and significantly extending the service life of the idler roller device 100. In addition, the gap provides space for the storage of lubricating medium 140, which enables the lubrication effect to last for a longer period of time, reduces the frequency of maintenance, and improves the reliability and economy of the idler roller device 100.

[0029] In some embodiments, each end cap 110 is provided with a powder filling hole 111, which allows the lubricating medium 140 to be injected simultaneously from both ends of the idler roller device 100, thereby improving lubrication efficiency and facilitating the uniform distribution of the lubricating medium 140.

[0030] In some embodiments, the inner diameter of the powder filling hole 111 is larger than the inner diameter of the first through hole 125; this allows the lubricating medium 140 to be smoothly introduced into the first lubrication passage through the connection between the powder filling hole 111 and the first through hole 125 after entering the roller device 100. The larger inner diameter of the powder filling hole 111 makes it easier for the operator to inject the lubricating medium 140, while reducing the injection resistance.

[0031] In some embodiments, the inner diameter of the first through hole 125 is larger than the inner diameter of the second through hole 126. This decreasing inner diameter design allows the lubricating medium 140 to flow sequentially from the powder filling hole 111 to the first through hole 125 and the second through hole 126, forming a progressively guided lubrication path. This decreasing inner diameter design effectively controls the flow rate of the lubricating medium 140, ensuring that it remains in each through hole for a sufficient time, thus fully filling each lubrication passage and ultimately reaching the mating surface between the screw shaft 124 and the idler roller sleeve 123. This design avoids the problem of the lubricating medium 140 failing to reach the mating surface smoothly due to excessive flow rate during circulation, and also prevents channel blockage.

[0032] In some embodiments, the inner diameter of the powder filling hole 111 is 14mm to 16mm; the inner diameter of the powder filling hole 111 can be 14mm, 14.5mm, 15mm, 15.5mm or 16mm. This ensures that the lubricating medium 140 can be smoothly injected into the receiving cavity from the powder filling hole 111, and also facilitates the operator to use the powder filling tool for injection.

[0033] In some embodiments, the inner diameter of the first through hole 125 is 4mm to 6mm; the inner diameter of the first through hole 125 can be 4mm, 4.5mm, 5mm, 5.5mm, or 6mm. This allows the lubricating medium 140 to smoothly enter the first through hole 125 from the powder filling hole 111, while the inner diameter of 4mm to 6mm can initially control the flow rate of the lubricating medium 140, preventing the lubricating medium 140 from flowing too fast and failing to effectively fill the first lubrication passage.

[0034] In some embodiments, the inner diameter of the second through hole 126 is 2.5mm to 3.5mm. The inner diameter of the second through hole 126 can be 2.5mm, 3mm, or 3.5mm. This allows the lubricating medium 140 to enter the second lubrication passage at an appropriate flow rate. The inner diameter of 2.5mm to 3.5mm ensures that the lubricating medium 140 can pass smoothly while also creating a certain pressure during passage, which helps the lubricating medium 140 diffuse between the mating surfaces.

[0035] Therefore, the inner diameters of the powder filling hole 111, the first through hole 125, and the second through hole 126 decrease step by step, which can ensure that the lubricating medium 140 maintains a stable flow rate and pressure during the flow process, and achieve the best lubrication effect.

[0036] In some embodiments, the first through hole 125 is a straight through hole, the axis of which is perpendicular to the axis of the inner sleeve 122 of the idler roller. That is, the straight through hole is opened radially along the inner sleeve 122 of the idler roller. The lubricating medium 140 enters the first through hole 125 radially from the receiving cavity, and the flow direction is perpendicular to the axis of the inner sleeve 122 of the idler roller. This structural design causes the flow direction of the lubricating medium 140 to change by 90 degrees when it enters the first through hole 125. However, the smooth wall of the straight through hole makes the flow resistance of this direction change small, and the lubricating medium 140 can flow smoothly from the receiving cavity into the first lubrication passage. The first through hole 125 is evenly arranged around the circumference of the inner sleeve 122 of the idler roller, which can ensure that the lubricating medium 140 enters the first lubrication passage from all sides of the inner sleeve 122 of the idler roller at the same flow rate, thereby improving the uniformity of the distribution of the lubricating medium 140.

[0037] In some embodiments, the second through hole 126 is an oblique through hole, with its axis forming a certain angle with the axis of the idler roller sleeve 123, ranging from 30° to 60°. The angle between the axis of the oblique through hole and the axis of the idler roller sleeve 123 can be 30°, 35°, 40°, 45°, 50°, or 60°. This allows the lubricating medium 140 to have a certain oblique flow component when entering the second lubrication passage. Several second through holes 126 are evenly arranged circumferentially along the idler roller sleeve 123. When the lubricating medium 140 enters the second lubrication passage through the oblique through holes, due to the oblique flow direction, the lubricating medium 140 can form a more uniform coverage on the mating surface between the screw shaft 124 and the idler roller sleeve 123, avoiding excessive accumulation in one area and insufficient distribution in other areas. The oblique angle of the through holes improves the uniformity and durability of the lubrication effect, ensuring good flow performance and stable lubrication effect in the lubrication passage.

[0038] In some embodiments, the sealing member 130 is a threaded member, and the inner wall of the powder filling hole 111 is provided with an internal thread that mates with the threaded member. The threaded member and the powder filling hole 111 are detachably connected via the threaded engagement. The internal thread on the inner wall of the powder filling hole 111 allows the sealing member 130 to be screwed into the powder filling hole 111 and fit tightly, achieving an effective sealing effect. The threaded connection of the sealing member 130 facilitates installation and disassembly, allowing operators to quickly open the powder filling hole 111 to inject or replenish the lubricating medium 140 when needed, and to quickly seal the powder filling hole 111 after injection. Furthermore, the threaded design allows the sealing member 130 to be reused, improving the economy and convenience of maintaining the idler roller device 100, and ensuring that the sealing performance does not significantly decrease during long-term use.

[0039] In some embodiments, the end cap 110 can be a ring-shaped part machined from a steel plate, with a Φ14.5mm powder filling hole 111 drilled on its surface and an M16×1.5 fine thread tapped inside the hole. The sealing part 130 can be two M16×1.5 304 heat-resistant steel bolts, each sealing one of the two powder filling holes 111.

[0040] In some embodiments, the roller body 121 can be cut from a 40Cr seamless steel pipe, the roller inner sleeve 122 can be cut from a 40Cr seamless steel pipe, and the roller bushing 123 can be cut from a ZG35Cr24Ni7SiN heat-resistant steel pipe.

[0041] In the second aspect of this application, as Figure 2 As shown, an installation method based on the above-described idler roller device 100 is provided, comprising the following steps: S100: Weld the idler body 121 and the idler inner sleeve 122 to the two end caps 110; It is understandable that the idler body 121 and the inner sleeve 122 are welded to the two end caps 110. In specific operation, the inner sleeve 122 is first placed between the two end caps 110, and its position is adjusted so that its axis coincides with the axis of the end caps 110. Then, the two ends of the inner sleeve 122 are fixedly connected to the two end caps 110 by welding. The welding method can be electric arc welding or argon arc welding. The weld should be uniform and continuous to ensure connection strength and sealing. The idler body 121 is sleeved on the outside of the inner sleeve 122, and the idler body 121 and the inner sleeve 122 are coaxially arranged, maintaining a preset gap between them to form a receiving cavity. The two ends of the idler body 121 are welded and fixed to the corresponding end caps 110, so that the idler body 121 and the inner sleeve 122 form a stable integral structure through the end caps 110. After welding, the weld should be inspected for quality to ensure there are no defects such as porosity or slag inclusions.

[0042] S200: The roller bushing 123 is inserted into the roller inner sleeve 122 along the axial direction of the roller inner sleeve 122; Understandably, the idler roller sleeve 123 is inserted axially into the inner sleeve 122 along the inner axis of the idler roller sleeve 122. The outer diameter of the idler roller sleeve 123 is smaller than the inner diameter of the inner sleeve 122, maintaining a gap of 1mm to 2mm between them, which forms the first lubrication passage. The idler roller sleeve 123 is inserted axially into the inner sleeve 122 from one end, and the axial position of the idler roller sleeve 123 is constrained by the through hole of the end cap 110. The end of the idler roller sleeve 123 protrudes from the through hole of the end cap 110. The lubricating medium 140 injected into the first lubrication passage later serves the purpose of lubrication and support.

[0043] S300: The screw shaft 124 is inserted into the roller sleeve 123 along the axial direction of the roller sleeve 123, and the shaft end of the screw shaft 124 is connected to the roller seat. Understandably, the screw shaft 124 is inserted into the idler sleeve 123 along its axial direction. The outer diameter of the screw shaft 124 is smaller than the inner diameter of the idler sleeve 123, with a gap of 0.4mm to 0.6mm between them, forming a second lubrication passage. The screw shaft 124 is inserted through the through hole of the end cover 110 and inserted axially into the idler sleeve 123. The shaft end of the screw shaft 124 is fixed to the idler seat by means of threaded connection, key connection, or spline connection, thereby realizing the overall installation of the idler device 100.

[0044] S400: Lubricating medium 140 is injected into the powder filling hole 111 of the end cap 110 so that the lubricating medium 140 flows into the second lubrication passage through the powder filling hole 111, the receiving cavity, the first through hole 125, the first lubrication passage, and the second through hole 126. After the injection is completed, the powder filling hole 111 is sealed by the sealing member 130.

[0045] Understandably, lubricating medium 140 is injected into the powder filling hole 111 of the end cap 110. The powder filling hole 111 is connected to the receiving cavity. After the lubricating medium 140 enters the receiving cavity through the powder filling hole 111, it flows into the first lubrication passage sequentially through the first through hole 125 under the action of gravity, and then into the second lubrication passage through the second through hole 126, finally reaching the mating surface between the screw shaft 124 and the idler roller bushing 123, forming a lubricating film between the mating surfaces. The injection process should be carried out slowly to ensure that the lubricating medium 140 can fully fill each level of lubrication passage. After the injection is completed, the sealing member 130 is screwed into the powder filling hole 111 and tightened. The sealing member 130 and the internal thread of the powder filling hole 111 cooperate to achieve a seal, preventing the lubricating medium 140 from leaking and external impurities from entering.

[0046] Therefore, the installation method of the idler roller device 100 of this application achieves a reliable connection between the idler roller body 121, the idler roller inner sleeve 122, and the end cover 110 through welding; it achieves the formation of multi-stage lubrication channels through clearance fit; and it achieves effective lubrication of the mating surfaces by injecting lubricating medium 140 through the powder filling hole 111. The entire installation process is simple and convenient, requiring no complicated special tools, and the installation quality is easy to guarantee. The injection process of lubricating medium 140 is combined with the installation process, reducing separate lubrication operation steps, improving installation efficiency, and ensuring that the idler roller device 100 has a good lubrication state before being put into use, avoiding the problem of initial wear caused by insufficient lubrication.

[0047] In the third aspect of this application, such as Figure 3 As shown, a lubrication method based on the above-described idler roller device 100 is provided, comprising the following steps: S10: Remove the sealing member 130 from the powder filling hole 111 and inject the lubricating medium 140 through the powder filling hole 111. The lubricating medium 140 flows into the second lubricating passage through the receiving cavity, the first through hole 125, the first lubrication passage, and the second through hole 126 in sequence to lubricate the mating surface between the idler roller bushing 123 and the screw shaft 124. Understandably, the sealing element 130 is removed from the powder filling hole 111 by the operator through rotation, exposing the passage of the powder filling hole 111. Then, lubricating medium 140 is injected through the powder filling hole 111. Under the action of gravity or pressure, the lubricating medium 140 flows sequentially through the receiving cavity and the first through hole 125 into the first lubrication passage, and then through the second through hole 126 into the second lubrication passage, finally reaching the mating surface between the idler roller bushing 123 and the screw shaft 124. The lubricating medium 140 forms a lubricating film between the mating surfaces, reducing wear caused by direct metal-to-metal contact.

[0048] S20: After injection, the powder filling hole 111 is sealed by the sealing component 130.

[0049] Understandably, after injection, the powder filling hole 111 is sealed by the sealing component 130. The sealing component 130 is screwed into the powder filling hole 111 and tightened to prevent the lubricating medium 140 from leaking and external impurities from entering.

[0050] S30: Repeat the above steps periodically.

[0051] It is understandable that since the lubricating medium 140 will be gradually consumed after the idler roller device 100 is used, the above steps are repeated periodically to inject the lubricating medium 140 through the powder filling hole 111 to ensure the lubrication effect between the idler roller bushing 123 and the screw shaft 124.

[0052] Therefore, this lubrication method can provide lubrication to the mating surfaces during the operation of the idler roller assembly 100. By periodically replenishing the lubricating medium 140, the integrity of the lubricating film between the mating surfaces is always maintained, significantly reducing the probability of wear and failure, and extending the service life of the idler roller assembly 100. This method is simple and convenient to operate, and lubrication maintenance can be completed without disassembling the idler roller assembly 100, reducing maintenance costs and downtime, and improving the utilization efficiency of the idler roller assembly 100.

[0053] In some embodiments, the lubricating medium 140 is coke powder, and the particle size of the lubricating medium 140 is 1mm to 3mm. Coke powder is a solid lubricant that can maintain stable lubrication performance under high temperature environments, is not prone to oxidation or deterioration, and is suitable for use under harsh working conditions. The particle size of the coke powder can be 1mm, 1.5mm, 2mm, 2.5mm, or 3mm. Coke powder of this particle size can pass smoothly through the first through hole 125 and the second through hole 126, avoiding the problem of channel blockage caused by excessively large particle size. The coke powder enters the receiving cavity through the powder inlet 111, and then is injected into the first lubrication passage through the first through hole 125, playing a lubricating and supporting role between the idler roller bushing 123 and the idler roller inner sleeve 122. Then it is injected into the second lubrication passage through the second through hole 126, playing a lubricating and supporting role between the idler roller bushing 123 and the screw shaft 124. In addition, the flow and breakage of the coke powder in the first and second lubrication passages reduces dry friction and achieves the lubrication effect.

[0054] Through the above embodiments, this application has the following beneficial effects or advantages: 1) The idler roller device 100 of this application, through the design of a multi-stage lubrication channel, realizes the step-by-step guidance and conveying of the lubricating medium 140 from the powder filling hole 111 to the mating surface of the idler roller bushing 123 and the screw shaft 124, which solves the problem of lubrication difficulties in the existing idler roller device 100 and improves the service life and operational stability of the idler roller device 100.

[0055] 2) When the idler roller device of this application impacts the 100 coke can: the coarse coke powder in the cavity absorbs 80% of the impact energy, and the vibration amplitude of the shaft system is reduced by 62%; after continuous operation, the coke powder is refined by friction and forms a 10-50μm graphite lubricating film on the shaft surface (the coefficient of friction is reduced to 0.15). 2) Compared with the average replacement cycle of 1 month for traditional idlers, the replacement cycle of the idler device 100 of this application can reach 36 months.

[0056] 3) The impact resistance of the idler roller device 100 in this application is improved: the coke powder cavity buffer reduces the peak stress of the idler roller by 45%; the lubrication effect is long-lasting: a single filling of coke powder can provide continuous lubrication for 6-8 months; the economy is improved: the annual maintenance cost is reduced by 76%, the coke powder is zero cost, and the downtime loss is reduced.

[0057] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0058] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0059] In this application, unless otherwise expressly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0060] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0061] Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents.

Claims

1. A roller device, characterized in that, include: Two end caps, each end cap having a powder filling hole, the end caps being annular in shape, and having a through hole in the middle of the end cap; An idler roller assembly includes an idler roller body, an idler roller inner sleeve, an idler roller bushing, and a screw shaft coaxially arranged. The idler roller body and the idler roller inner sleeve are spaced apart to form a receiving cavity communicating with a powder filling hole. The idler roller inner sleeve has a plurality of first through holes communicating with the receiving cavity along its circumference. The idler roller inner sleeve and the idler roller bushing are spaced apart to form a first lubrication passage communicating with the first through holes. The idler roller bushing has a plurality of second through holes communicating with the first lubrication passage along its circumference. The idler roller bushing and the screw shaft are spaced apart to form a second lubrication passage communicating with the second through holes. Both ends of the idler roller inner sleeve are welded to two end caps, and both ends of the idler roller body are welded to two end caps, respectively. The idler roller bushing and the screw shaft both pass through the through holes of the end caps, and the screw shaft passes through the idler roller bushing, and the screw shaft is used to connect to an idler roller seat. A number of sealing components, the same as the number of powder filling holes, are provided at the powder filling holes.

2. The idler roller device according to claim 1, characterized in that, The inner diameter of the through hole of the end cap is larger than the outer diameter of the roller bushing. The inner diameter of the inner sleeve of the idler roller is larger than the outer diameter of the outer sleeve of the idler roller shaft. The distance between the inner sleeve of the idler roller and the bushing of the idler roller is 1mm to 2mm.

3. The idler roller device according to claim 1, characterized in that, The inner diameter of the idler roller bushing is larger than the outer diameter of the screw shaft; The distance between the idler roller bushing and the screw shaft is 0.4mm~0.6mm.

4. The idler roller device according to any one of claims 1-3, characterized in that, Each of the end caps is provided with a powder filling hole; The inner diameter of the powder feeding hole is larger than the inner diameter of the first through hole; The inner diameter of the first through hole is larger than the inner diameter of the second through hole.

5. The idler roller device according to any one of claims 1-3, characterized in that, The inner diameter of the powder feeding hole is 14mm~16mm; The inner diameter of the first through hole is 4mm~6mm; The inner diameter of the second through hole is 2.5mm~3.5mm.

6. The idler roller device according to any one of claims 1-3, characterized in that, The first through hole is a straight through hole, and the second through hole is an angled through hole.

7. The idler roller device according to any one of claims 1-3, characterized in that, The sealing component is a threaded component, and the inner wall of the powder filling hole is provided with an internal thread that mates with the threaded component.

8. A method for installing a roller device according to any one of claims 1-7, characterized in that, Includes the following steps: The idler body and the idler inner sleeve are welded to the two end caps; The roller bushing is inserted into the inner sleeve of the roller along the axial direction. The screw shaft is inserted into the idler roller bushing along the axial direction, and the shaft end of the screw shaft is connected to the idler roller seat. Lubricating medium is injected into the powder filling hole of the end cap, so that the lubricating medium flows into the second lubrication passage through the powder filling hole, the receiving cavity, the first through hole, the first lubrication passage, and the second through hole. After the injection is completed, the powder filling hole is sealed by the sealing member.

9. A lubrication method for the idler roller device according to any one of claims 1-7, characterized in that, Includes the following steps: The sealing member is removed from the powder filling hole, and the lubricating medium is injected from the powder filling hole. The lubricating medium flows into the second lubricating passage through the receiving cavity, the first through hole, the first lubrication passage, and the second through hole in sequence to lubricate the mating surface between the idler roller bushing and the screw shaft. After injection is completed, the powder injection hole is sealed by the sealing component; Repeat the above steps periodically.

10. The lubrication method for the idler roller device according to claim 9, characterized in that, The lubricating medium is coke powder, and the particle size of the lubricating medium is 1mm to 3mm.

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