Corundum armor three-resistance carrier roller

Abstract

The utility model discloses a corundum armor three-resistance carrier roller which comprises a roller which is fixed on a tubular shaft and can rotate along with the tubular shaft, the roller is made of plastic, ceramic blocks are fixedly arranged on the outer surface of the roller at intervals, and the ceramic blocks and the plastic are integrally formed in one step through injection molding. Compared with an existing ceramic carrier roller, the ceramic carrier roller is light in weight, the weight of the ceramic carrier roller can be reduced by 50-70%, the ceramic carrier roller is high in mechanical strength, corrosion resistance and impact resistance and small in mechanical abrasion, the service life of the ceramic carrier roller reaches 8-10 years, mechanical transmission is stable and reliable when the ceramic carrier roller is used, and conveying efficiency is high. The ceramic roller can normally work in the environment with high corrosion and oxidizability, the ceramic blocks and the roller are made into a whole in an injection molding mode, firmness and reliability are achieved, and materials are saved.

Description

Technical Field

[0001] This utility model relates to conveyor components, and more particularly to idlers on belt conveyors. Background Technology

[0002] As is well known, belt conveyors are a type of transmission equipment with large conveying capacity, high transmission efficiency, low transmission cost, and the advantages of being dust-free, low-noise, and unrestricted by terrain, climate, and environmental factors, enabling long-distance, long-term continuous transmission. Idler rollers are a crucial and numerous component in belt conveyors, and their service life and performance directly affect the conveyor's transmission efficiency and operating costs. Traditional belt conveyors mostly use steel pipe idlers, but steel pipe idlers are prone to rust and corrosion during actual use, have low wear resistance, short service life, and require frequent replacement, increasing maintenance time, raising the conveyor's operating costs, and reducing its transmission efficiency. Currently, most belt conveyor idler rollers are made of integral ceramic. Although this improves wear resistance and extends service life, integral ceramic rollers are heavy, consume more power, and have low impact resistance. During belt operation, especially when the belt starts, the inertial vibration of the belt can easily cause the roller to break. The second type uses screws to fix wear-resistant ceramic blocks to steel pipes to make rollers. This method is more troublesome to process and install, and the ceramic blocks are prone to loosening and falling off, requiring frequent replacement of the ceramic blocks, which affects the working efficiency of the conveyor and increases the conveying cost. Utility Model Content

[0003] In view of the problems existing in the belt conveyor idlers of the prior art, this utility model provides a corundum armor three-resistant idler that is not only high in strength, corrosion resistance, impact resistance and wear resistance, and long service life, but also low in operating cost and high in conveying efficiency.

[0004] The technical solution adopted by this utility model to solve the technical problem is: the corundum armor three-resistant roller includes a roller fixed on the tube shaft and capable of rotating with the tube shaft. The roller is made of plastic, and ceramic blocks are fixedly arranged at intervals on the outer surface of the roller. The ceramic blocks and the plastic are integrally formed by injection molding.

[0005] The ceramic block is corundum ceramic, and the shape of the ceramic block is square, rectangular, triangular, circular or other polygonal; the ceramic blocks are arranged in a cross shape or a triangular shape (preferably triangular) and are fixed on the outer surface of the roller in parallel or staggered intervals.

[0006] Before the ceramic blocks and plastic rollers are integrally molded by injection molding, they are pre-assembled to form the upper half model, lower half model, and core mold of the roller model. The ceramic blocks are then fixed in the slots of the holding net, and the holding nets with the ceramic blocks assembled are fixed on the upper half model and lower half model respectively. Finally, the mold is closed to form the roller cavity. Figure 3 (The middle arrow indicates the mold opening and closing direction). After plastic is injected into the mold on the injection molding machine, the holding mesh melts into the molten plastic. The ceramic block is in contact with the molten plastic on three sides and is fixed in the plastic on the outer surface of the roller. After holding pressure, cooling and opening the mold, a roller with ceramic blocks fixedly embedded on the outer surface of the plastic is obtained. The roller is then assembled with other mechanical parts to form a support roller (including flat support rollers and inclined support rollers).

[0007] The holding net is made of plastic of the same or similar material as the roller. When in use, the flat upper and lower holding nets are bent into an arc shape that is the same or similar to the roller.

[0008] The ceramic blocks are fixed to the upper and lower half-modules forming the cylinder cavity by a holding net made of the same or similar plastic as the cylinder.

[0009] The ceramic block described in this utility model is made of corundum ceramic material with an alumina content of 90%, which gives the ceramic block high compressive strength, high hardness and impact resistance. The compressive strength is above 250MPa (referred to as high-strength ceramic block in this industry), the Mohs hardness is above 9, the thermal stability is high and the resistance to acid and alkali corrosion is strong.

[0010] The ceramic blocks are preferably pre-embedded and fixed to the outer surface of the roller in a triangular shape, forming an armor-like outer layer. This creates a wear-resistant, impact-resistant, corrosion-resistant, and oxidation-resistant surface layer on the outer surface of the roller that comes into contact with the belt. The roller is made of polypropylene plastic, but other higher-strength plastics (such as ABS) can also be used.

[0011] Compared with existing ceramic idlers, this utility model has the following advantages:

[0012] 1. This utility model is not only lightweight (reducing weight by 50-70% compared to ceramic rollers), but also has high mechanical strength, strong corrosion resistance, good impact resistance, low mechanical wear, and a service life of 8-10 years.

[0013] 2. The mechanical transmission is smooth and reliable during use, with high transmission efficiency, and can operate normally in environments with high corrosiveness and oxidation.

[0014] 3. The ceramic block and plastic roller are injection molded into a single unit, which is both sturdy and reliable, and saves materials. Attached Figure Description

[0015] Figure 1 This is a half-sectional structural diagram of the present invention.

[0016] Figure 2 yes Figure 1 A schematic diagram of a partial cross-sectional view of the AA structure.

[0017] Figure 3 This is a schematic diagram of the model structure before roller forming.

[0018] Figure 4 This is a partial cross-sectional view of the holding mesh used to fix ceramic blocks onto the molding die.

[0019] In the diagram, 1. Roller; 2. Ceramic block; 3. Inner ring body; 4. Tube shaft; 5. Rotating shaft; 6. Bearing seat; 7. Bearing; 8. Inner seal; 9. Outer end cover; 10. Shaft retaining ring; 11. Upper half module; 12. Holding net; 13. Positioning slot; 14. Injection port; 15. Roller cavity; 16. Inner ring body cavity; 17. Core mold; 18. Movable block; 19. Positioning block; 20. Groove; 21. Spline groove; 22. Spline teeth. Detailed Implementation

[0020] exist Figure 1 and Figure 2 In this embodiment, the corundum armor three-resistant idler roller includes a roller 1, which is fixed on a tube shaft 4 and can rotate with the tube shaft 4. An inner ring 3 is integrally formed inside the roller, and spline grooves 21 are spaced apart within the inner ring 3. Spline teeth 22 that match the spline grooves are provided on the tube shaft. The roller is fixedly connected via the spline teeth and spline grooves. Bearing seats 6 are fixed inside both ends of the tube shaft, located inside the roller at both ends. The bearing seats are fixed on a rotating shaft 5, and both ends of the rotating shaft are movably supported on a conveyor frame. Bearings 7 are provided inside the bearing seats, and one end of the bearing seat is fixed to the rotating shaft by a shaft retainer 10. The shaft is equipped with an inner seal 8 for bearings. The roller has outer end caps 9 at both ends. The outer end caps are fixed to the shaft with shaft retainers. The roller is made of plastic such as polyethylene and ABS. The roller and the tube shaft are also fixed and connected by other methods (such as fixing the roller to the tube shaft with threaded retainers). The roller can also be directly fixed to the shaft (i.e., the tube shaft is omitted). The inner ring body can also be omitted inside the roller. Corundum ceramic blocks 2 are fixedly arranged at intervals on the outer surface of the roller. The ceramic blocks and the plastic roller are formed into a whole by injection molding.

[0021] The ceramic blocks are made of corundum ceramic and are square, rectangular, triangular, circular, or other polygonal in shape. The ceramic blocks are arranged in a cross or triangular (preferably triangular) pattern, and are fixed to the outer surface of the roller in parallel or staggered intervals. Square ceramic blocks with dimensions of 10-15 × 10-15 × 6-8 mm are preferred.

[0022] exist Figure 3 and Figure 4In the process, before the ceramic block and the roller are integrally injection molded by an injection molding machine, the upper half model 11, the lower half model (not shown in the figure), and the core mold 17 of the roller model are pre-assembled. The ceramic block is fixed in the slots of the upper and lower holding nets respectively. Then, the holding net 12 with the ceramic block installed is fixed on the upper half model and the lower half model respectively. Then, the two half models and the core mold 17 are closed to form the roller cavity 15. An injection port 14 is provided between the core mold and the upper half model. After plastic is injected into the mold on the injection molding machine, the holding net melts into the molten plastic. The ceramic block is in contact with the molten plastic on three sides and is fixed in the plastic on the outer surface of the roller. After holding pressure and cooling, the mold is opened to obtain a roller with ceramic blocks embedded in the outer surface of the plastic. Then, it is assembled with other mechanical parts to form a roller (including flat rollers and inclined rollers). The holding net is made of a single piece of plastic that is the same as or similar to that used for the roller. In use, the planar holding net can be bent into an arc shape similar to or similar to that of the roller. The holding net has slots 20 spaced at intervals corresponding to the number and position of the ceramic blocks. The ceramic blocks are fixed in the slots. The holding net is fixed to the two halves of the injection molding machine by the matching of positioning blocks 19 and positioning slots 13 on the two halves of the mold. Then, the half-molds and the core mold are joined. When the roller has an inner ring, the core mold forming the inner ring has movable blocks 18, forming an inner ring cavity 16 between the movable blocks. After injection molding, the inner ring cavity and the roller cavity 15 form a roller 1 with an inner ring inside. The connection structure of the roller and other mechanical parts assembled into a support roller described in this utility model is all prior art.

[0023] The above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to specific embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of the technical solution of this utility model, and all such modifications or substitutions should be covered within the scope of protection of the claims of this utility model.

Claims

1. A corundum armored three-resistant idler roller, comprising a drum (1) fixed on a tube shaft and capable of rotating with the tube shaft, characterized in that: The roller is made of plastic, and ceramic blocks (2) are fixedly arranged at intervals on the outer surface of the roller. The ceramic blocks and the plastic are integrally formed by injection molding.

2. The corundum armor three-resistant idler roller according to claim 1, characterized in that: The ceramic block (2) is fixed to the upper half module (11) and the lower half module, which can form the cylinder cavity (15), respectively, by a holding net (12) made of plastic that is the same as or similar to the cylinder.

3. The corundum armor three-resistant idler roller according to claim 1, characterized in that: The ceramic block (2) is square, rectangular, triangular or circular in shape.

4. The corundum armor three-resistant idler roller according to claim 1, characterized in that: The ceramic blocks (2) are arranged in a triangular pattern and fixed on the outer surface of the roller (1).

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