A conveying belt tear quick flexible connection repair tool and process

Abstract

The present application belongs to the technical field of conveying belt maintenance and repair, and particularly relates to a conveying belt tearing quick flexible connection repair tool and process. The process comprises: operation surface construction; tearing stress release and homing; accurate positioning and slotting; cleaning, gluing, and installation of the conveying belt connecting piece for riveting; surface finishing, sealing, and curing maintenance. The cold vulcanized repair glue scraped after the repair of the present application can completely cover the joint between the connecting piece and the conveying belt body and the tiny gap of the stepped hole, form a seamless sealing layer, block water, oil stains, and dust from penetrating into the repair interface; at the same time, the glue forms an elastic transition layer, disperses the local stress of the interface part to the periphery, and relieves the fatigue cracking under alternating load. The repair process of the present application can be adapted to the fabric core conveying belt and the steel wire rope core conveying belt, can select the corresponding specification of the blooming rivet according to the strength grade of the conveying belt and the number of the stepped hole, and can meet the on-site repair needs of the longitudinal tearing of the ordinary strength and high strength conveying belts.

Description

Technical Field

[0001] This invention belongs to the field of conveyor belt maintenance and repair technology, specifically relating to a quick and flexible connection repair tooling and process for conveyor belt tearing. Background Technology

[0002] Belt conveyors, as core equipment in modern industrial material handling systems, are widely used in mining, ports, power, metallurgy, and building materials industries, offering advantages such as large conveying capacity, long conveying distance, and simple structure. The conveyor belt, as the load-bearing and traction component of the belt conveyor, accounts for approximately 30%-50% of the total investment, making it the most expensive and easily worn component in the conveying system.

[0003] Because conveyor belts operate under high loads and high volumes continuously for extended periods, and often in extremely harsh environments (such as underground mines, exposed to direct sunlight, and subject to material impact), they are highly susceptible to various types of damage. Among these, longitudinal tearing is one of the most serious and destructive failure modes. When a conveyor belt is jammed or impacted by sharp materials, once a tear occurs, it tends to spread rapidly along the length of the belt, causing extensive damage and even forcing the entire production line to shut down.

[0004] Current maintenance and repair technologies for conveyor belt damage mainly fall into three categories: mechanical repair methods (such as clamping and splinting), cold bonding repair methods (cold vulcanization), and hot vulcanization repair methods. Mechanical repair method: This method typically uses metal clips or clamps to connect the torn sections. Although simple to operate, it damages the belt structure, causes stress concentration, results in low strength at the joint, and easily damages the rollers. It should only be used as a temporary emergency measure.

[0005] Cold bonding repair method: This method uses chemical adhesives and repair strips to bond the damaged area. It has extremely high requirements for the construction environment (must be water-free and dust-free), and the bonding strength is greatly affected by the process, with a long curing time and lower durability than hot vulcanization.

[0006] Hot vulcanization repair method: The repair material is fused to the belt by heating and pressurizing in a vulcanizing machine. Although the repair strength is the highest, the equipment is bulky, energy-intensive, and the repair time is extremely long (usually several hours to more than ten hours), which seriously affects production efficiency and is difficult to meet the needs of rapid on-site repair of long longitudinal tears.

[0007] In summary, existing conveyor belt longitudinal tear repair technologies generally suffer from the following bottlenecks: 1. Difficulty in positioning: After longitudinal tearing occurs, the belts on both sides of the tear are prone to misalignment and shrinkage. The traditional method of positioning by manually pulling is difficult to ensure alignment accuracy, resulting in uneven belt surface after repair and causing deviation problem.

[0008] 2. Non-standard incision: When dealing with irregular natural tears, manual incision repair relies entirely on the operator's experience, resulting in inconsistent incision quality. This leads to inadequate embedding of repair materials and stress concentration at the interface.

[0009] 3. Repairs require too much time, and simple repairs do not achieve the desired strength, making them prone to cracking or tearing again.

[0010] Therefore, developing a conveyor belt longitudinal tear repair process that can achieve rapid positioning, standardized cutting, and is simple to operate and takes less time is of great practical significance for reducing enterprise maintenance costs and ensuring production safety. Summary of the Invention

[0011] To address the technical problems existing in the above-mentioned maintenance and repair technologies, the present invention provides a tooling and process for rapid flexible connection repair of conveyor belt tears.

[0012] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A quick and flexible repair tooling for conveyor belt tears includes a conveyor belt support platform, a conveyor belt repair and stretching mechanism, a positioning and grooving mechanism, a conveyor belt connecting piece, and rivets. The conveyor belt support platform includes two sets of X-shaped lifting structures, a top support platform, and bottom elastic clamps; the top support platform is equipped with a longitudinal slide rail; the two sets of X-shaped lifting structures are respectively equipped with bottom elastic clamps, and the two sets of X-shaped lifting structures are arranged at intervals along the length of the conveyor belt. The X-shaped lifting structures are used to lift the conveyor belt to form a suspended repair working surface. The conveyor belt repair and stretching mechanism includes a ratchet-type bidirectional tensioner, a belt clamping jaw, and a ratchet wrench. The belt clamping jaw is located at both ends of the ratchet-type bidirectional tensioner and is used to clamp the two sides of the conveyor belt. The ratchet-type bidirectional tensioner, together with the ratchet wrench, can stretch or squeeze the tear in the conveyor belt to achieve alignment. The positioning and grooving mechanism includes a guide rail base, upper and lower double milling cutter heads, a depth limiting device, a load-bearing anvil, a positioning and grooving support platform, and a slide rail mounted on the positioning and grooving support platform; the guide rail base and the load-bearing anvil can be slidably mounted on the slide rail; the upper and lower double milling cutter heads are mounted on the guide rail base, and the depth limiting device is used to control the milling and grooving depth; the load-bearing anvil can move along the slide rail to below the area to be repaired, serving as a rigid backing for grooving and riveting operations; The conveyor belt connecting piece is a prefabricated component, including an aramid fabric reinforcement layer in the middle and pre-cast hot-vulcanized rubber layers on both sides; the conveyor belt connecting piece has 24 stepped holes, which can accommodate rivet heads so that the rivet heads do not protrude from the surface of the connecting piece. The rivet includes a semi-hollow rivet and a steel ball welded and fixed to the tail of the semi-hollow rivet; the rivet as a whole is adapted to the stepped hole, and when the head of the semi-hollow rivet is struck, the steel ball squeezes the semi-hollow inner cavity of the semi-hollow rivet, causing the tail of the semi-hollow rivet to expand outward and form a mechanical lock.

[0013] The X-shaped lifting structure is a scissor-type lifting frame, which uses a screw or hydraulic drive to change the cross angle of the articulated arms to achieve vertical lifting; the bottom elastic clamp is a clamp-type locking structure, which can quickly lock onto the conveyor beam, achieving disassembly and assembly without drilling or welding.

[0014] The ratchet-type bidirectional tensioner adopts a ratchet and pawl one-way locking structure. By changing the screw rotation direction, it can switch between tension and compression modes. After releasing the ratchet wrench, it can maintain the current tension state and prevent the conveyor belt from elastically retracting and running off track.

[0015] The upper and lower double milling cutter heads of the positioning and grooving mechanism are synchronously driven by the same drive shaft to achieve synchronous milling of the upper and lower surfaces of the conveyor belt; the depth limiting device limits the depth of the milled groove to 3mm; the milled groove is an elliptical groove with the long axis along the longitudinal direction of the conveyor belt.

[0016] The load-bearing anvil is a steel plate, which is placed under the conveyor belt during riveting operations to help the steel balls enhance the expansion and forming effect of the semi-hollow rivet tail.

[0017] The stepped hole is a countersunk hole structure. After the semi-hollow rivet is installed, the rivet head is completely sunk into the countersunk hole, flush with or lower than the surface of the conveyor belt connecting piece.

[0018] A rapid and flexible repair process for conveyor belt tears, using the aforementioned rapid and flexible repair tooling for conveyor belt tears, includes the following steps: S1. Construction of the working surface: Fix the bottom elastic clamps of the two sets of X-type lifting structures of the conveyor belt support platform to the crossbeam of the belt conveyor. The two sets of X-type lifting structures are arranged at intervals along the length of the conveyor belt. Simultaneously drive the two sets of X-type lifting structures to lift the conveyor belt section to be repaired, forming a suspended and stable repair working surface. S2. Tear stress release and realignment: Clamp the belt clamping jaws at both ends of the conveyor belt repair and stretching mechanism to the edges of the conveyor belt on both sides of the tear; operate the ratchet wrench, depending on the state of the tear, pull outward to flatten the stacked conveyor belt, or squeeze inward to bring the two sides of the tear closer together, eliminate the stress in the tear area, and complete the tear alignment. S3. Precise positioning and grooving: Place the positioning and grooving mechanism above the conveyor belt to be repaired; move the guide rail base, and slide the guide rail base along the slide rail so that the center line of the mechanism is aligned with the longitudinal tear center line of the conveyor belt; move the load-bearing anvil along the slide rail and place it under the area to be grooved; start the upper and lower double milling cutter heads to simultaneously mill grooves on the upper and lower surfaces of the conveyor belt tear. S4. Cleaning, applying adhesive, and installing conveyor belt connecting pieces for riveting: Clean and remove impurities from the milled grooves, stepped holes, and tear surfaces; after the cleaning agent has evaporated, apply cold vulcanizing adhesive to the grooves and stepped holes; embed the conveyor belt connecting pieces into the corresponding upper and lower grooves, ensuring that the stepped holes of the connecting pieces are concentrically aligned with the holes machined on the conveyor belt; insert the rivets, with the semi-hollow rivet heads housed inside the stepped holes; strike the semi-hollow rivet heads, and with the rigid support of the load-bearing anvil, the steel balls squeeze the tail of the semi-hollow rivets outwards, forming a mechanical lock inside the conveyor belt; S5. Surface finishing, sealing and curing: Grind the surface of the repair area and remove dust; apply cold vulcanized repair material to completely cover the conveyor belt connecting piece and its joints; allow to cure at room temperature; after curing, grind and repair the surface until it is flat and smooth.

[0019] The groove obtained by milling in step S3 is an elliptical groove with its long axis along the longitudinal direction of the conveyor belt and its depth controlled at 3mm.

[0020] In step S4, when the conveyor belt is a fabric core belt with a strength ≤1000N / mm, a fine semi-hollow rivet is selected and 23 stepped holes are used; when the conveyor belt is a high-strength or steel wire rope core belt with a strength >1000N / mm, a thicker and longer semi-hollow rivet is selected and all 24 stepped holes are used. In step S4, the cleaning process involves using a belt cleaner to scrub the inner surface of the groove, the inner wall of the stepped hole, and the cross-sections on both sides of the tear to remove rubber powder, oil, moisture, and oxide layer.

[0021] In step S5, the cold vulcanized repair rubber coating covers the conveyor belt connecting piece and the seam, and extends 1015mm in all directions; the rubber coating thickness fills the depressions, making the repair position flush with the original surface of the conveyor belt; the scraper is used to scrape the conveyor belt surface at an angle of 45°~60°. Step S5 Curing and Maintenance Stage: When the ambient temperature is ≥20℃, the curing time shall not be less than 2 hours; when the ambient temperature is <10℃, infrared heating shall be used for auxiliary curing or the curing time shall be extended to more than 4 hours; during the curing process, the conveyor belt shall not be moved or a load shall be applied.

[0022] Compared with the prior art, the beneficial effects of this invention are: 1. The present invention provides a conveyor belt repair and stretching mechanism. Relying on the unidirectional locking characteristics of the ratchet and pawl of the ratchet-type bidirectional tensioner, it can stretch and flatten or squeeze and close the tear according to the actual condition of the tear. After adjustment, the tension can be maintained even when the ratchet wrench is released, overcoming the problems of conveyor belt elastic shrinkage and misalignment shrinkage. It does not require continuous manual pulling and fixing, ensuring that the reference on both sides of the tear is aligned, and avoiding conveyor belt deviation failure caused by interface misalignment after repair from the source.

[0023] 2. This invention employs a positioning and grooving mechanism, with simultaneous milling by upper and lower dual milling heads and a depth limiting device. This allows irregularly shaped natural tears to be uniformly processed into elliptical grooves with controllable depth. A load-bearing anvil is placed under the conveyor belt to prevent the rubber belt from elastically sinking during milling, ensuring consistent grooving depth on the upper and lower surfaces of the conveyor belt. This eliminates the limitations of manual trimming experience, ensuring uniform groove shape and depth, guaranteeing a full fit between the conveyor belt connecting piece and the groove, reducing stress concentration at the interface, and lowering the risk of re-cracking at the repair site.

[0024] 3. The conveyor belt connecting piece of this invention uses an aramid fabric reinforcement layer combined with pre-cast hot-vulcanized rubber layers on both sides. On the one hand, it relies on cold vulcanizing mortar to achieve chemical bonding at the rubber molecular level; on the other hand, it uses rivets to form a mechanical lock. The load-bearing anvil acts as a rigid backing for riveting, significantly improving the expansion rate of the rivet ends, and the strength of the repaired joint can reach 80%-90% of the original rated strength of the conveyor belt. Furthermore, the stepped holes in the connecting piece are countersunk holes, with the rivet heads completely retracted inside the stepped holes. After repair, there are no rivet protrusions on the belt surface, preventing the rivets from scratching the rollers, idlers, and cleaners. At the same time, the large flat surface of the stepped holes can disperse the rivet clamping force, preventing local rubber from being crushed and damaged.

[0025] 4. The conveyor belt support platform of the present invention relies on the X-shaped lifting structure and the bottom elastic clamp to lock onto the crossbeam of the belt conveyor. No on-site welding or drilling is required, and a stable suspended repair working surface can be quickly built. The whole set of tooling is a modular combination structure. Compared with traditional large hot vulcanizing machine equipment, the handling and assembly efficiency is high. It does not require a long-term high-temperature vulcanization process, which significantly shortens the on-site repair operation time and reduces the production losses caused by unplanned equipment downtime.

[0026] 5. The cold-cured repair adhesive applied after the repair is completed in this invention can completely cover the joint between the connecting piece and the conveyor belt body, as well as the tiny gaps in the stepped holes, forming a seamless sealing layer that prevents water, oil, and dust from penetrating into the repair interface. At the same time, the adhesive forms an elastic transition layer that disperses the local stress at the interface to the surrounding area, alleviates fatigue cracking under alternating loads, and effectively extends the service life of the repaired position.

[0027] 6. The repair process of this invention can be adapted to fabric core conveyor belts and steel cord core conveyor belts. It can select the corresponding specifications of flower rivets and the number of stepped holes according to the strength grade of the conveyor belt, taking into account the on-site repair needs of longitudinal tears of ordinary strength and high strength conveyor belts. It is suitable for various on-site operation environments such as mines, ports, and power plants. Attached Figure Description

[0028] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0029] The structures, proportions, sizes, etc. illustrated in this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed herein, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0030] Figure 1 This is a schematic diagram of the conveyor belt support platform arrangement of the present invention; Figure 2 This is a schematic diagram of the conveyor belt support platform of the present invention; Figure 3 This is a schematic diagram of the conveyor belt repair and stretching mechanism of the present invention; Figure 4 This is a schematic diagram of the positioning and slotting mechanism of the present invention; Figure 5 This is a schematic diagram of the structure of the conveyor belt connecting piece of the present invention; Figure 6 This is a schematic diagram of the structure of the rivet of the present invention; Figure 7 This is a process flow diagram of the present invention.

[0031] Wherein: 1 is the conveyor belt support platform, 101 is the X-type lifting structure, 102 is the top support platform, 103 is the bottom tension clamp, 104 is the longitudinal slide rail, 2 is the conveyor belt repair and stretching mechanism, 201 is the ratchet-type bidirectional tensioner, 202 is the belt clamping jaw, 203 is the ratchet wrench, 3 is the positioning and grooving mechanism, 301 is the guide rail base, 302 is the depth limiting device, 303 is the load-bearing anvil, 304 is the positioning and grooving support platform, 305 is the slide rail, 4 is the conveyor belt connecting piece, 401 is the stepped hole, 5 is the rivet, 501 is the semi-hollow rivet, and 502 is the steel ball. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. These descriptions are only for further illustrating the features and advantages of the present invention, and not for limiting the claims of the present invention. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0033] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0034] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0035] This embodiment provides a quick and flexible connection repair tool for conveyor belt tears, which mainly includes a conveyor belt support platform 1, a conveyor belt repair and stretching mechanism 2, a positioning and grooving mechanism 3, a conveyor belt connecting piece 4, and rivets 5.

[0036] like Figure 1 , Figure 2 As shown, the conveyor belt support platform 1 includes two sets of X-shaped lifting structures 101, a top support platform 102, and bottom elastic clamps 103. The top support platform 102 is equipped with a longitudinal slide rail 104. The two sets of X-shaped lifting structures 101 are respectively equipped with bottom elastic clamps 103. The two sets of X-shaped lifting structures 101 are arranged at intervals along the length of the conveyor belt. During operation, the bottom elastic clamps 103 are used to clamp and lock onto the crossbeam of the belt conveyor without drilling or welding. The X-shaped lifting structure 101 is a scissor-type lifting frame, which is driven by a screw or hydraulic system. Vertical lifting is achieved by changing the cross angle of the articulated arms. By synchronously driving the two sets of X-shaped lifting structures 101, the section of the conveyor belt to be repaired can be lifted to form a suspended and stable repair working surface.

[0037] like Figure 3As shown, the conveyor belt repair and stretching mechanism 2 includes a ratchet-type bidirectional tensioner 201, a belt clamping jaw 202, and a ratchet wrench 203. The belt clamping jaw 202 is respectively located at both ends of the ratchet-type bidirectional tensioner 201 and is used to clamp the edges of the conveyor belt on both sides of the tear. The ratchet-type bidirectional tensioner 201 adopts a ratchet and pawl one-way locking structure. By changing the screw rotation direction, it switches between two working modes: stretching and squeezing. In conjunction with the ratchet wrench 203, it completes the stretching and flattening or squeezing and aligning of the tear. After releasing the ratchet wrench 203, the ratchet and pawl structure can maintain the existing tension to prevent the conveyor belt from elastically retracting and causing the tear to misalign again.

[0038] like Figure 4 As shown, the positioning and grooving mechanism 3 includes a guide rail base 301, upper and lower double milling cutter heads, a depth limiting device 302, a load-bearing anvil 303, a positioning and grooving support platform 304, and a slide rail 305 mounted on the positioning and grooving support platform 304; the guide rail base 301 and the load-bearing anvil 303 can be slidably mounted on the slide rail 305; the positioning and grooving mechanism 3 has its own independent positioning and grooving support platform 304 and slide rail 305, which are independent of the longitudinal slide rail 104 of the conveyor belt support table 1, and there is no assembly relationship between the two; the upper and lower double milling cutter heads are mounted on... Mounted on the guide rail base 301, the upper and lower double milling cutter heads are synchronously driven by the same drive shaft, enabling synchronous milling of the upper and lower surfaces of the conveyor belt; the depth limiting device 302 is used to control the milling groove depth, limiting the milling groove depth to 3mm, and the milled groove is an elliptical groove with the long axis along the longitudinal direction of the conveyor belt; the load-bearing anvil 303 is made of steel plate, and the load-bearing anvil 303 can be moved along the slide rail 305 to the area to be repaired, preventing the belt from elastically sinking during grooving operations, and serving as a rigid backing during riveting operations to improve the opening expansion rate of the opening rivets.

[0039] like Figure 5 As shown, the conveyor belt connecting piece 4 is a factory prefabricated part. The middle layer of the conveyor belt connecting piece 4 is an aramid cloth reinforcement layer, and the two sides are pre-cast hot vulcanized rubber layers. The conveyor belt connecting piece 4 has 24 stepped holes 401. The stepped holes 401 are countersunk holes. After the rivets 5 are installed, the heads of the rivets 5 can be completely stored inside the stepped holes 401. The heads of the rivets 5 are flush with or lower than the surface of the conveyor belt connecting piece 4, ensuring that the surface of the conveyor belt is flat after repair.

[0040] like Figure 6 As shown, the rivet 5 includes a semi-hollow rivet 501 and a steel ball 502. The steel ball 502 is welded and fixed to the inner cavity of the tail of the semi-hollow rivet 501. When the head of the semi-hollow rivet 501 is struck, the steel ball 502 is squeezed into the inner cavity of the tail of the semi-hollow rivet 501, forcing the tail of the semi-hollow rivet 501 to expand outward to form a barb. Relying on the rigid support of the load-bearing anvil 303, the tail of the rivet is fully expanded and formed, so as to achieve reliable mechanical locking.

[0041] This invention also provides a rapid and flexible repair process for conveyor belt tears, using the aforementioned tooling for repair, such as... Figure 7 As shown, the work steps are as follows: S1. Construction of the working surface: The bottom elastic clamps 103 of the two sets of X-type lifting structures 101 on the conveyor belt support platform 1 are locked and fixed to the crossbeam of the belt conveyor. The two sets of X-type lifting structures 101 are arranged at intervals along the length of the conveyor belt. The two sets of X-type lifting structures 101 are driven synchronously to lift the conveyor belt section to be repaired upward to form a suspended and stable repair working surface. During the operation, the lifting height of the two sets of X-type lifting structures 101 is consistent to avoid the conveyor belt from twisting.

[0042] S2. Tear Stress Release and Repositioning: Clamp the belt clamping jaws 202 at both ends of the conveyor belt repair and stretching mechanism 2 onto the edges of the conveyor belt on both sides of the tear. Operate the ratchet wrench 203. Depending on the actual state of the tear, if the conveyor belts are stacked and overlapping, stretch outward to flatten the stacked parts; if the tear gap is too large, squeeze inward to bring the two sides of the tear closer together, eliminate the internal stress in the tear area, and complete the alignment and positioning of the tear.

[0043] S3. Precise positioning and grooving: Place the positioning and grooving mechanism 3 above the conveyor belt to be repaired; move the guide rail base 301, which slides along the slide rail 305, so that the center line of the mechanism is precisely aligned with the longitudinal tear center line of the conveyor belt; move the load-bearing anvil 303 along the slide rail 305 and place it directly below the area to be grooved; start the upper and lower double milling cutter heads to simultaneously mill an elliptical groove with a long axis along the longitudinal direction of the conveyor belt and a depth of 3mm on the upper and lower surfaces of the conveyor belt tear.

[0044] S4. Cleaning, applying adhesive, and installing the conveyor belt connecting piece 4 for riveting: Use belt cleaner to scrub the milled grooves, the inner walls of the stepped holes 401, and the two sides of the tear to thoroughly remove rubber powder, oil, moisture, and oxide layers; after the cleaner has completely evaporated, evenly apply cold vulcanizing adhesive that matches the conveyor belt rubber to the grooves and the inner walls of the stepped holes 401, and let it dry until the adhesive reaches a dry film state that is not sticky but still tacky; embed the conveyor belt connecting piece 4 into the corresponding upper and lower elliptical grooves respectively, ensuring that the conveyor belt connecting piece 4 is completely in contact with the bottom of the groove, and at the same time, make the stepped holes 401 of the conveyor belt connecting piece 4 concentrically aligned with the holes formed by the conveyor belt body; insert the rivet 5, with the head of the semi-hollow rivet 501 placed inside the countersunk hole of the stepped hole 401; tap the head of the semi-hollow rivet 501, and the steel ball 502 squeezes the tail of the semi-hollow rivet 501 outward, forming a mechanical lock inside the conveyor belt with the rigid support of the load-bearing anvil 303.

[0045] S5. Surface Finishing, Sealing, and Curing: Use a grinding tool to grind the surface of the repair area and remove rubber dust. Apply cold vulcanizing repair material using a scraper, ensuring the material completely covers the conveyor belt connecting piece 4 and the seam, extending 10-15mm outwards. Apply the material at a 45°~60° angle to the conveyor belt surface, filling in depressions to make the repair area flush with the original surface of the conveyor belt. Then allow it to cure at room temperature. When the ambient temperature is ≥20℃, the curing time should be no less than 2 hours. When the ambient temperature is <10℃, use infrared heating to assist curing, or extend the curing time to more than 4 hours. During the curing period, do not move the conveyor belt or apply load to it. After the material has completely cured, grind and finish the repair surface to remove scraper marks and burrs, making the repair area smooth and flat.

[0046] Example 1: Repair of fabric core conveyor belt, conveyor belt strength 800N / mm≤1000N / mm The object to be repaired is a fabric-core conveyor belt with a rated strength of 800 N / mm, which has suffered a longitudinal tear. Steps S1 and S3 are performed to complete the work surface setup, tear alignment, and milling of the elliptical groove. In step S4, fine-gauge semi-hollow rivets 501 are selected, and the rivets are riveted using the 23 stepped holes 401 on the conveyor belt connecting piece 4. The head of the semi-hollow rivet 501 is struck, and the steel ball 502 compresses and expands the tail of the rivet to lock it in place. After riveting, cleaning, adhesive application, and cold vulcanizing repair adhesive are performed. The ambient temperature is 22℃, and curing is carried out for 2 hours. After curing, grinding and finishing complete the repair. The strength of the repaired joint can reach 80%-90% of the original conveyor belt's rated strength.

[0047] Example 2: Repair of steel wire rope core conveyor belt, conveyor belt strength 1600N / mm > 1000N / mm The object to be repaired is a high-strength steel wire rope conveyor belt with a rated strength of 1600 N / mm, which has a longitudinal tear. Steps S1 and S3 are performed to complete the work surface setup, align the tear, and mill a 3mm deep elliptical groove. Step S4 involves selecting thickened and lengthened semi-hollow rivets 501 and riveting them using all 24 stepped holes 401 on the conveyor belt connecting piece 4. Cleaning, applying adhesive, and scraping repair adhesive are then completed. With an ambient temperature of 8℃, infrared heating lamps are turned on for 4 hours of curing. After curing, grinding and finishing are performed, and the repair is complete.

[0048] The above description only illustrates the preferred embodiments of the present invention. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention, and all such changes should be included within the protection scope of the present invention.

Claims

1. A quick and flexible repair tool for conveyor belt tears, characterized in that: It includes a conveyor belt support platform (1), a conveyor belt repair and stretching mechanism (2), a positioning and grooving mechanism (3), a conveyor belt connecting piece (4), and rivets (5); The conveyor belt support platform (1) includes two sets of X-shaped lifting structures (101), a top support platform (102), and a bottom elastic clamp (103); the top support platform (102) is provided with a longitudinal slide rail (104); the two sets of X-shaped lifting structures (101) are respectively equipped with bottom elastic clamps (103), and the two sets of X-shaped lifting structures (101) are arranged at intervals along the length of the conveyor belt. The X-shaped lifting structures (101) are used to lift the conveyor belt to form a suspended repair working surface; The conveyor belt repair and stretching mechanism (2) includes a ratchet-type bidirectional tensioner (201), a belt clamping jaw (202), and a ratchet wrench (203); the belt clamping jaw (202) is located at both ends of the ratchet-type bidirectional tensioner (201) and is used to clamp the two sides of the conveyor belt. The ratchet-type bidirectional tensioner (201) works with the ratchet wrench (203) to stretch or squeeze the tear in the conveyor belt for alignment. The positioning and grooving mechanism (3) includes a guide rail base (301), upper and lower double milling cutter heads, a depth limiting device (302), a load-bearing anvil (303), a positioning and grooving support platform (304), and a slide rail (305) provided on the positioning and grooving support platform (304); the guide rail base (301) and the load-bearing anvil (303) can be slidably mounted on the slide rail (305); the upper and lower double milling cutter heads are installed on the guide rail base (301), and the depth limiting device (302) is used to control the milling and grooving depth; the load-bearing anvil (303) can move along the slide rail (305) to below the area to be repaired, serving as a rigid backing for grooving and riveting operations; The conveyor belt connecting piece (4) is a prefabricated part, including an aramid cloth reinforcement layer in the middle and pre-cast hot vulcanized rubber layers on both sides; the conveyor belt connecting piece (4) has 24 stepped holes (401), the stepped holes (401) can accommodate the head of the rivet (5) so that the head of the rivet (5) does not protrude above the surface of the connecting piece (4). The rivet (5) includes a semi-hollow rivet (501) and a steel ball (502) welded and fixed to the tail of the semi-hollow rivet (501); the rivet (5) is adapted to the stepped hole (401). When the head of the semi-hollow rivet (501) is struck, the steel ball (502) squeezes the semi-hollow inner cavity of the semi-hollow rivet (501), causing the tail of the semi-hollow rivet (501) to expand outward and form a mechanical lock.

2. The quick and flexible connection repair tooling for conveyor belt tears according to claim 1, characterized in that: The X-shaped lifting structure (101) is a scissor-type lifting frame, which uses a screw or hydraulic drive to change the cross angle of the articulated arm to achieve vertical lifting; the bottom elastic clamp (103) is a clamp-type locking structure, which can be quickly locked on the crossbeam of the belt conveyor to achieve disassembly and assembly without drilling or welding.

3. The quick flexible connection and repair tooling for conveyor belt tears according to claim 1, characterized in that: The ratchet-type bidirectional tensioner (201) adopts a ratchet and pawl one-way locking structure. By changing the screw rotation direction, it can switch between tension and compression modes. After releasing the ratchet wrench (203), it can maintain the current tension state and prevent the conveyor belt from elastically retracting and running out of position.

4. The quick and flexible connection repair tooling for conveyor belt tears according to claim 1, characterized in that: The upper and lower double milling cutter heads of the positioning and grooving mechanism (3) are synchronously driven by the same drive shaft to realize synchronous milling of the upper and lower surfaces of the conveyor belt; the depth limiting device (302) limits the depth of the milled groove to 3mm; the milled groove is an elliptical groove with the long axis along the longitudinal direction of the conveyor belt.

5. The quick and flexible connection repair tooling for conveyor belt tears according to claim 1, characterized in that: The load-bearing anvil (303) is a steel plate, which is placed under the conveyor belt during riveting operations to help the steel ball (502) lift the tail of the semi-hollow rivet (501) to expand and form.

6. The quick and flexible connection repair tooling for conveyor belt tears according to claim 1, characterized in that: The stepped hole (401) is a countersunk hole structure. After the semi-hollow rivet (501) is installed, the rivet head is completely sunk into the countersunk hole, and is flush with or lower than the surface of the conveyor belt connecting piece (4).

7. A rapid and flexible connection repair process for conveyor belt tears, characterized in that, Repairing conveyor belt tears using the quick flexible connection repair tooling as described in any one of claims 16 includes the following steps: S1. Construction of working surface: Fix the bottom elastic clamps (103) of the two sets of X-type lifting structures (101) of the conveyor belt support platform (1) to the crossbeam of the belt conveyor. The two sets of X-type lifting structures (101) are arranged at intervals along the length of the conveyor belt. Simultaneously drive the two sets of X-type lifting structures (101) to lift the conveyor belt section to be repaired and form a suspended and stable repair working surface. S2, Tear stress release and repositioning: Clamp the belt clamping jaws (202) at both ends of the conveyor belt repair and stretching mechanism (2) to the edges of the conveyor belt on both sides of the tear; operate the ratchet wrench (203) to stretch outward to flatten the stacked conveyor belt, or squeeze inward to bring the two sides of the tear closer together, eliminate the stress in the tear area, and complete the tear alignment. S3, Precise positioning and grooving: The positioning and grooving mechanism (3) is arranged above the conveyor belt to be repaired; the guide rail base (301) is moved and slid along the slide rail (305) so that the center line of the mechanism is aligned with the longitudinal tear center line of the conveyor belt; the load-bearing anvil (303) is moved along the slide rail (305) and placed under the area to be grooved; the upper and lower double milling cutter heads are started to mill grooves on the upper and lower surfaces of the conveyor belt tear simultaneously; S4. Cleaning and applying adhesive and installing the conveyor belt connecting piece (4) for riveting: Clean the milled groove, the inner wall of the stepped hole (401), and the tear section; after the cleaning agent evaporates, apply cold vulcanizing adhesive to the inner wall of the groove and the stepped hole (401); embed the conveyor belt connecting piece (4) into the corresponding grooves on the upper and lower sides, so that the stepped hole (401) of the connecting piece is concentrically aligned with the hole processed by the conveyor belt; insert the rivet (5), and the head of the semi-hollow rivet (501) of the rivet (5) is housed inside the stepped hole (401); knock the head of the semi-hollow rivet (501), and with the rigid support of the load-bearing anvil (303), the steel ball (502) squeezes the tail of the semi-hollow rivet (501) to expand outward, forming a mechanical lock inside the conveyor belt; S5. Surface finishing, sealing and curing: Grind the surface of the repair area and remove dust; apply cold vulcanized repair material to completely cover the conveyor belt connecting piece (4) and its joints; allow to stand at room temperature for curing; after curing, grind and repair the surface until it is flat and smooth.

8. The rapid flexible connection repair process for conveyor belt tears according to claim 7, characterized in that, The groove obtained by milling in step S3 is an elliptical groove with its long axis along the longitudinal direction of the conveyor belt and its depth controlled at 3mm.

9. The rapid flexible connection repair process for conveyor belt tears according to claim 7, characterized in that, In step S4, when the conveyor belt is a fabric core belt with a strength ≤1000N / mm, a fine-gauge semi-hollow rivet (501) is selected, and 23 stepped holes (401) are used; when the conveyor belt is a high-strength or steel wire rope core belt with a strength >1000N / mm, a thickened and lengthened semi-hollow rivet (501) is selected, and all 24 stepped holes (401) are used. In step S4, the inner surface of the groove, the inner wall of the stepped hole (401), and the cross-sections on both sides of the tear are cleaned with belt cleaner to remove rubber powder, oil, moisture and oxide layer.

10. The rapid flexible connection repair process for conveyor belt tears according to claim 7, characterized in that, In step S5, the cold vulcanized repair rubber coating covers the conveyor belt connecting piece (4) and the seam, and extends 1015mm in all directions; the rubber coating thickness fills the depression, so that the repair position is flush with the original surface of the conveyor belt; the scraper is used to scrape the conveyor belt surface at an angle of 45°~60°. Step S5 Curing and Maintenance Stage: When the ambient temperature is ≥20℃, the curing time shall not be less than 2 hours; when the ambient temperature is <10℃, infrared heating shall be used for auxiliary curing or the curing time shall be extended to more than 4 hours; during the curing process, the conveyor belt shall not be moved or a load shall be applied.

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