Rotary kiln carrier roller
Through the integrated roll and roller shaft design, the problem of stress concentration of rotary kiln rollers is solved, the overall strength and safety of the rollers are improved, and the stable operation of the equipment is ensured.
Patent Information
- Application Number
- CN202422245470.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-13
- Publication Date
- 2025-08-01
- Estimated Expiration
- 2034-09-13
AI Technical Summary
The split structure design of the existing rotary kiln sling rollers leads to concentrated stress during operation of the roller wheel and roller shaft, which is prone to fracture, affecting the safety of the equipment.
The integrated roll and roller shaft design is adopted. The diameter of the roller shaft gradually increases and is co-linear with the roller axis. The roller and roller shaft are made of ZG310-570 cast steel. A rubber ring is installed on the outside. It is processed through the CNC integrated forming process to increase the overall strength and torque bearing capacity.
Effectively disperse stress, prevent stress concentration in the journal area of the roller shaft, improve the overall strength of the roller, ensure safe operation of the equipment, and reduce the risk of roller shaft breakage.
Smart Images
Figure CN223179259U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the technical field of rotary kilns, and particularly to a rotary kiln idler roller. Background Art
[0002] A rotary kiln is a common industrial equipment widely used in multiple industries such as building materials, metallurgy, and chemical engineering. Its main function is to process various solid materials through high-temperature treatment and chemical reactions. After the materials enter the kiln from the kiln tail, as the kiln body slowly rotates, the materials continuously roll in the axial and radial directions and gradually move forward. In this process, the materials are subjected to the effects of high-temperature radiation and heat conduction, gradually generating a liquid phase and undergoing chemical reactions, and finally generating the required products.
[0003] The structure of a rotary kiln mainly includes the following parts:
[0004] Kiln barrel: Usually made of low-carbon steel plate with a thickness between 15 and 30 mm, having good fire resistance and mechanical strength.
[0005] Drive device: Driven by gears and a transmission system to rotate the kiln body at a certain angle.
[0006] Combustion equipment: Used to provide the required high-temperature environment.
[0007] Supporting tires (riding rings) and idler rollers: Used to support the kiln body and ensure its stable operation.
[0008] Internal heat exchanger: Used to improve the thermal efficiency and control the temperature distribution.
[0009] The kiln barrel of a rotary kiln is driven by driving idler rollers. Traditional idler rollers include roller wheels, idler roller shafts (rotating shafts), and bearing seats. The roller wheels are sleeved on the idler roller shafts, and both ends of the idler roller shafts are rotatably connected in two bearing seats.
[0010] During the operation of a rotary kiln, if the kiln body of the rotary kiln is not concentric, and coupled with a large load of materials inside the kiln body of the rotary kiln, it will continuously generate uneven stress on the roller wheels and idler roller shafts in the idler rollers, which will cause stress concentration between the roller wheels and the idler roller shafts. For the above-mentioned split-designed idler rollers, during the rotation of the rotary kiln, an unreasonable interference fit situation will occur between the roller wheels and the idler roller shafts of the rotary kiln. The interference fit amount between the roller wheels and the idler roller shafts is generally 0.6‰ to 1‰ of the shaft diameter to ensure that the roller wheels and the idler roller shafts do not become loose. However, this interference fit amount will cause the idler roller shafts to neck down at the ends of the roller holes on the roller wheels. The necking area of the idler roller shafts is very likely to have stress concentration during the operation of the rotary kiln, resulting in the fracture of the idler roller shafts, which is not conducive to the safe operation of the equipment. Utility Model Content
[0011] This application provides a rotary kiln idler roller, which can effectively solve the problems existing in the commonly used split-structured idler rollers in the prior art.
[0012] The above object of the present application is achieved by the following technical solutions:
[0013] A rotary kiln idler includes a roller integrally formed and a idler shaft that can be used to be installed in a bearing housing. The number of the idler shafts is two, and the diameters of the two idler shafts are both smaller than the diameter of the roller;
[0014] The two idler shafts are respectively horizontally arranged on the outer sides of both ends in the axial direction of the roller axis, and the axes of the two idler shafts and the axis of the roller are collinear;
[0015] The diameter of the idler shaft near one end of the roller is larger than the diameter of the other opposite end of the idler shaft.
[0016] Further, the idler shaft includes a first shaft section, a second shaft section and a third shaft section that are fixedly connected in sequence along the horizontal direction, and the diameters of the first shaft section, the second shaft section and the third shaft section increase in sequence. One end of the third shaft section far from the second shaft section is fixedly connected to the center of one end in the axial direction of the roller.
[0017] Further, chamfering treatments are performed on the circumferences of the connection part between the third shaft section and the roller and the connection part between the second shaft section and the third shaft section.
[0018] Further, the overall length of the idler shaft is smaller than the width of the roller.
[0019] Further, on both end faces of the roller in the axial direction, outside the connection areas with the corresponding third shaft sections on their corresponding sides, an annular groove is provided, and there is a gap between the mutually approaching ends of the two annular grooves.
[0020] Further, a plurality of through holes penetrating through are uniformly arranged along the circumferential direction in the annular groove.
[0021] Further, the length of the through hole is greater than the depth of the annular groove.
[0022] Further, the materials of the integrally formed roller and idler shaft are ZG310-570.
[0023] Further, a rubber ring is sleeved outside the roller, and the inner diameter of the rubber ring is slightly smaller than the outer diameter of the roller.
[0024] In summary, the present application includes at least one of the following beneficial technical effects:
[0025] The idler roller of the rotary kiln in this application is integrally formed as a whole. Compared with the prior art in which the roller and the idler roller shaft are designed in a split manner, the torque that the roller and the idler roller shaft can withstand during use is increased, and the overall strength of the roller and the idler roller shaft of the rotary kiln is improved. In this way, during operation, the entire idler roller can effectively disperse the stress exerted by the rotary kiln body and the materials inside it, thereby preventing the stress of the split idler roller from concentrating in the necking area of the idler roller shaft during operation and causing fracture failures, so as to ensure the safe operation of the equipment. Brief Description of the Drawings
[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present application. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.
[0027] Figure 1 is a cross-sectional view of the roller in the split idler roller in the prior art;
[0028] Figure 2 is a front view of the roller in the split idler roller in the prior art;
[0029] Figure 3 is a side view of the idler roller shaft in the split idler roller in the prior art;
[0030] Figure 4 is a schematic diagram of a part of the roller in the integral idler roller of this application when it is in a cut-open state;
[0031] Figure 5 is a front view of the overall structure of the integral idler roller of this application.
[0032] Reference numerals: 1, roller; 2, idler roller shaft; 21, first shaft section; 22, second shaft section; 23, third shaft section; 3, annular groove; 4, through hole. Detailed Embodiments
[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present application clearer, the following clearly and completely describes the technical solutions in the embodiments of the present application. Obviously, the described embodiments are some, but not all, of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts also belong to the scope of protection of the present application.
[0034] Such as Figure 4 and Figure 5As shown, a rotary kiln roller disclosed in the present application includes an integrally formed roller 1 and a roller shaft 2 that can be installed in a bearing seat. There are two roller shafts 2, and the diameters of the two roller shafts 2 are smaller than the diameter of the roller 1; the two roller shafts 2 are horizontally arranged on the outer sides of the two ends of the roller 1 in the axial direction, and the axes of the two roller shafts 2 and the axis of the roller 1 are collinear; the diameter of the roller shaft 2 close to one end of the roller 1 is larger than the diameter of the other opposite end of the roller shaft 2.
[0035] In the above embodiment, the roller 1 and the roller shaft 2 of the present application can be preferably produced by CNC integrated molding process, and the roller 1 and the roller shaft 2 are formed and processed at one time using a complete metal block. The roller of the integrated structure produced in this way is better than the roller of the split design in the prior art (such as Figures 1-3 As shown, the roller 1 and the roller shaft 2 are two separate units, which are subsequently assembled using an interference fit. This significantly improves the overall strength of the roller and effectively disperses the stress previously concentrated on the roller and the roller shaft 2. This effectively prevents the roller shaft 2 from necking at both ends of the roller 1 axis after the interference fit is completed with the roller 1. In actual use, this prevents the stress generated by the rotary kiln body and the material inside from being concentrated in the necking area of the roller shaft 2, increasing the risk of the roller shaft 2 breaking and affecting the safe operation of the entire equipment.
[0036] The diameters of the two idler shafts 2 of the present invention are both smaller than the diameter of the roller 1. This allows the outer contour of the roller 1 to be in a convex state between the two idler shafts 2, so that the roller 1 can smoothly contact the kiln body of the rotary kiln, thereby supporting and synchronously rotating the kiln body. The diameter of the idler shaft 2 at one end near the roller 1 is larger than the diameter at the other opposite end. This allows the entire idler to be supported by a small-diameter bearing seat, which can reduce production costs to a certain extent.
[0037] The axes of the two roller shafts 2 and the axis of the roller 1 are collinear, so when the two roller shafts 2 and the roller 1 rotate synchronously, the rotary kiln body can rotate smoothly on the roller 1.
[0038] Furthermore, if Figure 4 As shown, the roller shaft 2 includes a first shaft segment 21, a second shaft segment 22 and a third shaft segment 23 which are fixedly connected in sequence along the horizontal direction, and the diameters of the first shaft segment 21, the second shaft segment 22 and the third shaft segment 23 increase in sequence, and the third shaft end is fixedly connected to the center of one end of the roller 1 in the axial direction away from one end of the second shaft segment 22.
[0039] In the above embodiment, when machining the roller shaft 2, the stepped first shaft segment 21, the second shaft segment 22 and the third shaft segment 23 can be machined by selecting a suitable tool, adjusting the lathe speed and feed rate, and using the tool radius compensation function or a combination of these methods. The third shaft segment 23 with the largest diameter is located close to the roller 1 side, which can increase the contact area of the entire roller shaft 2 and the roller 1 at the junction, increase the strength of their connection, and prevent the stress generated by the rotary kiln body and the internal material during the working process from causing the roller shaft 2 to break in the middle of the roller. According to common sense in physics, when the middle position of the horizontal rod supported at both ends is compressed, the force on the middle area of the horizontal rod will be the greatest, and the closer to the two ends, the smaller the force will be. Therefore, the present application sets the first shaft segment 21 with the smallest diameter at the edge, and the second shaft segment 22 with a diameter between the first shaft segment 21 and the third shaft segment 23 is set between the third shaft segment 23 and the first shaft segment 21.
[0040] Furthermore, if Figure 4 As shown, the peripheral sides of the connection portion between the third shaft segment 23 and the roller 1 and the peripheral sides of the connection portion between the second shaft segment 22 and the third shaft segment 23 are both chamfered.
[0041] In the above embodiments, the connections between the second shaft segment 22 and the third shaft segment 23, and between the third shaft segment 23 and the roller 1 of the present application are all rounded, so that the transition between them is smoother, which facilitates the transmission of the force exerted on the roller 1 to the bearing seats at both ends, and reduces the risk of the roller 1 being broken at the connection between the second shaft segment 22, the third shaft segment 23 and the roller 1 due to the pressure exerted on the roller 1.
[0042] Furthermore, if Figure 4 As shown, the overall length of the roller shaft 2 is smaller than the width of the roller 1.
[0043] In the above embodiments, the length of the roller shaft 2 is smaller than the width of the roller 1, which can increase the force-bearing area of the entire roller, reduce the length of the suspended part of the entire roller, and further improve the overall strength of the entire roller of this application.
[0044] Furthermore, if Figure 4 and Figure 5 As shown, an annular groove 3 is provided on both end faces of the roller 1 along the axial direction at the outer sides of the connection areas with the corresponding third shaft segments 23, and a gap exists between the two annular grooves 3 at their adjacent ends.
[0045] In the above embodiments, the two annular grooves 3 provided on the roller 1 in the present application in the above manner can reduce the weight of the entire roller 1 while ensuring a sufficiently large contact surface between the outer contour of the roller 1 and the kiln body of the rotary kiln, thereby reducing the force on the roller shaft 2.
[0046] Furthermore, ifFigure 5 As shown, a plurality of through holes 4 are evenly arranged along the circumferential direction of the annular groove 3.
[0047] In the above embodiments, the plurality of through holes 4 can further reduce the weight of the entire roller 1.
[0048] Furthermore, as Figure 4 shown, the length of the through hole 4 is greater than the depth of the annular groove 3.
[0049] In the above embodiments, since there is a gap between adjacent through holes 4 and the length of the through hole 4 is greater than the depth of the annular groove 3, the thickness of the region between the through holes 4 will also be greater than the thickness of the annular groove 3. In the roller 1, the region between the through holes 4 can provide a stable supporting force to the region of the roller 1 outside the annular groove 3 through the region of the roller 1 inside the annular groove 3, ensuring that the overall roller 1 will not easily deform during operation.
[0050] Furthermore, the integrally formed roller 1 and the idler shaft 2 are made of ZG310-570.
[0051] In the above embodiments, ZG310-570 is a kind of cast steel material, its yield strength is 310 MPa, and its tensile strength is 570 MPa. This material has a low cost in the production process, but has a very high strength, excellent toughness and plasticity, and is especially suitable for making steel castings.
[0052] Furthermore, a rubber ring is sleeved outside the roller 1, and the inner diameter of the rubber ring is slightly smaller than the outer diameter of the roller 1.
[0053] In the above embodiments, the inner diameter of the rubber ring is slightly smaller than the outer diameter of the roller 1. When the rubber ring is sleeved outside the roller 1, the rubber ring will be expanded by the roller 1 to generate an elastic force, which can tightly connect the rubber ring and the roller 1 together. And when the roller 1 is working, the rubber ring can increase the friction between it and the rotary kiln body to prevent slipping when they rotate synchronously.
[0054] The implementation principle of this embodiment is as follows: In the production of this application, the CNC integral forming process can be preferably used to integrally form the roller 1 and the idler shaft 2 from a complete metal block at one time. The made idler installs its idler shaft 2 in the bearing seat, and the outer contour of the roller 1 contacts the body of the rotary kiln. Compared with the prior art in which the roller 1 and the idler shaft 2 are designed in a split manner, the integrally designed idler in this application increases the torque that the roller 1 and the idler shaft can withstand during use, improves the overall strength of the roller 1 and the idler shaft 2 of the rotary kiln, so that during operation, the entire idler can effectively disperse the stress exerted by the rotary kiln body and the materials inside it, thereby preventing the stress of the split idler from concentrating in the necking area of the idler shaft 2 during operation and causing fracture failure, so as to ensure the safe operation of the equipment.
[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements 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 application.
Claims
1. A rotary kiln idler, characterized in that: It includes an integrally formed roller (1) and a roller shaft (2) that can be used to be installed in a bearing housing. The number of the roller shafts (2) is two, and the diameters of the two roller shafts (2) are both smaller than the diameter of the roller (1). The two roller shafts (2) are respectively horizontally arranged outside both ends in the axial direction of the roller (1), and the axes of the two roller shafts (2) are collinear with the axis of the roller (1). The diameter of one end of the roller shaft (2) close to the roller (1) is larger than the diameter of the other opposite end of the roller shaft (2).
2. The rotary kiln idler according to claim 1, wherein: The roller shaft (2) includes a first shaft section (21), a second shaft section (22) and a third shaft section (23) that are fixedly connected in sequence along the horizontal direction, and the diameters of the first shaft section (21), the second shaft section (22) and the third shaft section (23) increase in sequence. One end of the third shaft section far from the second shaft section (22) is fixedly connected to the center of one end in the axial direction of the roller (1).
3. The rotary kiln idler according to claim 2, wherein: The circumferences of the connection part between the third shaft section (23) and the roller (1) and the connection part between the second shaft section (22) and the third shaft section (23) are both rounded.
4. The rotary kiln idler according to claim 1, wherein: The overall length of the roller shaft (2) is smaller than the width of the roller (1).
5. The rotary kiln idler according to claim 3, wherein: On both end faces of the roller (1) in the axial direction, outside the connection areas with the corresponding third shaft sections (23) on their respective sides, there is an annular groove (3) provided, and there is a gap between the mutually approaching ends of the two annular grooves (3).
6. The rotary kiln idler according to claim 5, wherein: A plurality of through holes (4) are evenly arranged along the circumferential direction in the annular groove (3).
7. The rotary kiln idler according to claim 6, wherein: The length of the through hole (4) is greater than the depth of the annular groove (3).
8. The rotary kiln idler according to any one of claims 1 to 7, characterized in that: The integrally formed roller (1) and roller shaft (2) are made of ZG310-570.
9. The rotary kiln idler according to any one of claims 1 to 7, characterized in that: A rubber ring is sleeved outside the roller (1), and the inner diameter of the rubber ring is slightly smaller than the outer diameter of the roller (1).