Device for replacing carrier roller

Abstract

The utility model relates to a device for replacing a carrier roller, which is characterized by comprising an equipment base for providing stable support and installing a lifting unit; the lifting unit is used for installing the bearing unit and providing supporting force for the bearing unit; and the bearing unit is used for changing the supporting length and the supporting angle of the device, and the bearing unit is installed on the upper portion of the lifting unit. The device has the advantages that the electric control unit is adopted to control the electric push rod to realize the action of the device, so that the time for maintaining and replacing the carrier roller of the belt conveyor is shortened, and the working efficiency is improved; and meanwhile, the device is suitable for replacing the carrier rollers of the belt conveyors with various belt widths and groove type angles, so that the equipment acquisition cost is saved for enterprises.

Description

Technical Field

[0001] This utility model relates to the field of belt conveyor idler maintenance technology, specifically to a device for replacing idlers that can be used for replacing idlers of various belt conveyor models. Background Technology

[0002] In material handling processes in industries such as metallurgy and mining, belt conveyors are the most important material handling equipment due to their high transportation efficiency. However, during the continuous transportation operation of belt conveyors, idlers, as key components, often suffer from various forms of damage. This damage may cause increased running resistance of the belt conveyor, increased power consumption, and wear, slippage, or even tearing of the conveyor belt, resulting in low material handling efficiency or even production stoppage. Therefore, it is necessary to repair and replace idlers in a timely manner during routine belt conveyor maintenance.

[0003] In the maintenance and repair of belt conveyors, existing technologies require multiple people to work together to replace idlers. This involves using levers to pry up the conveyor belt above the idler or using jack-like tools to remove the idler from below. These methods require clearing material from the conveyor belt before operation, and the tools are mostly manually operated. When replacing trough idlers, intermediate idlers, and return idlers, workers must crawl under the conveyor, increasing the risk of accidents such as crushing and impacts. The replacement process requires 2-4 workers, resulting in high labor intensity, slow speed, and long processing times, significantly impacting production efficiency. Furthermore, many tools on the market are "specifically designed" for specific belt conveyors, necessitating the purchase of multiple tools for conveyor belts with varying widths, idler angles, and models, greatly increasing costs. Therefore, there is an urgent need to develop a safe, efficient, and applicable device for replacing idlers in various types of belt conveyors, so as to reduce the time, labor, economic losses, and safety accidents caused by damage to transportation equipment and downtime during daily maintenance and repair. Summary of the Invention

[0004] The main purpose of this utility model is to provide a roller replacement device that can be used to replace rollers of multiple belt conveyors at the same time, improve the replacement method of belt conveyor rollers, and solve the problems of high labor intensity, slow replacement speed and poor safety of existing roller replacement operations.

[0005] This utility model is implemented as follows. A device for replacing idler rollers according to this utility model is characterized by comprising: a base for providing stable support and mounting a lifting unit; a lifting unit for mounting a bearing unit and providing support force to the bearing unit; and a bearing unit for changing the support length and support angle of the device, wherein the bearing unit is mounted on the upper part of the lifting unit.

[0006] Preferably, the equipment base includes two main beams, a battery compartment, and a control unit. The two main beams are composed of two inward-opening channel steels, with symmetrical slide rails provided in each channel steel. The battery compartment and the control unit are respectively located at both ends of the two main beams.

[0007] Preferably, the lifting unit includes four first electric push rods, four moving sliders, two slider connecting shafts, and a pair of first and second transmission rods arranged in a cross configuration.

[0008] The first electric push rod is symmetrically fixed to the inner sidewalls of the slide rails of the two main beams with bolts, using the centerline of the two main beams as the axis. The moving slider is a hollow slider with a shaft hole, which is slidably engaged in the slide rails of the two main beams. The telescopic end of the first electric push rod is provided with a trunnion hole, and the two corresponding moving sliders are hinged to the trunnion hole of the telescopic end of the first electric push rod through a slider connecting shaft. The first transmission rod is a straight rod, and the second transmission rod is a straight rod with a groove in the middle. The upper and lower ends of the first and second transmission rods are respectively provided with shaft holes. The shaft holes at the lower ends of the first and second transmission rods are hinged in the two main beams through a slider connecting shaft.

[0009] Preferably, the bearing unit consists of a telescopic horizontal support mechanism and a flip-type grooved support mechanism.

[0010] The telescopic horizontal support mechanism includes a rectangular horizontal support frame I, a rectangular horizontal support frame II, and a second electric push rod. The rectangular horizontal support frame I is a rectangular hollow steel section with openings at both ends. The horizontal support frame II is an inwardly rolled channel steel with a cross-sectional area smaller than that of the horizontal support frame I and an opening facing downwards. The horizontal support frame II is inserted into the horizontal support frame I and is slidably connected to it. The power end of the second electric push rod is fixed to the rectangular horizontal support frame I with bolts, and its telescopic end is fixedly connected to the left end of the right-side flip-type channel support mechanism. Trunnions are provided on the outer sides of both ends of the horizontal support frame I and the horizontal support frame II. A groove matching the size of the trunnion is also provided at the open end of the horizontal support frame I. The upper ends of the first and second transmission rods of the lifting unit are respectively hinged to the trunnions at both ends of the rectangular horizontal support frame I and the horizontal support frame II.

[0011] Two flip-type grooved support mechanisms are symmetrically arranged at the left and right ends of the telescopic horizontal support mechanism. Each mechanism consists of a grooved support frame with one closed end, a third electric push rod, an adjusting plate, pins A, B, and C, and a grooved support plate. A shaft hole A and a sliding groove are respectively opened on the frame of the grooved support frame. The second electric push rod is bolted to the base plate inside the grooved support frame. The grooved support plate consists of an integrally formed upper cover plate and two side plates. A shaft hole B is opened in the lower part of the side plates, and a lower shaft hole C is opened in the lower part. The adjusting plate is located between the grooved support frame and the side plates. An upper shaft hole and a lower shaft hole are respectively opened in the upper and lower parts of the adjusting plate. The left grooved support frame... The closed end is fixedly connected to the left end of the horizontal support frame I, and the closed end of the right-side channel support frame is fixedly connected to the right end of the horizontal support frame II. The telescopic end of the second electric push rod is provided with a trunnion hole. The pin A passes through the slide groove A, the lower shaft hole of the adjusting plate, and the trunnion hole of the telescopic end of the second electric push rod, respectively, and hinges the telescopic end of the second electric push rod and the lower end of the adjusting plate in the channel support frame. The pin B passes through the shaft hole B opened in the lower middle part of the two side plates of the channel support plate and the upper shaft hole of the adjusting plate, respectively, and hinges the upper end of the adjusting plate to the lower middle part of the two side plates. The pin C passes through the shaft hole A opened on the frame of the channel support frame and the shaft hole C opened in the lower part of the two side plates, respectively, and hinges the lower part of the channel support plate in the channel support frame.

[0012] The advantages of this utility model are:

[0013] Compared with existing technologies, the advantages of this utility model are its novel concept and simple, reasonable structure. Multiple conveyor belt idler rollers of different models can be replaced by a single person and a single piece of equipment. Furthermore, the worker only needs to operate the controller to control the electrified conveyor belt support operation during the replacement process, greatly saving manpower and avoiding safety accidents such as squeezing and impacts that are prone to occur during operation. Therefore, this utility model can significantly reduce the time required for the maintenance and replacement of conveyor belt idler rollers, improve work efficiency, reduce labor intensity, and save on maintenance equipment and labor costs, bringing significant social and economic benefits to industries such as metallurgy, coal mining, and grain production. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the non-working state of the device for replacing idler rollers according to this utility model;

[0015] Figure 2 This is a schematic diagram of the structure of the device for replacing idler rollers of the present invention when replacing 10° to 45° trough idler rollers, transition idler rollers and intermediate idler rollers;

[0016] Figure 3This is a schematic diagram of the structure of the device for replacing idler rollers according to this utility model when replacing parallel idler rollers and return idler rollers;

[0017] Figure 4 This is a schematic diagram of the structure of the device for replacing idlers in this utility model when used on idlers of a long-width belt conveyor.

[0018] Figure 5 This is a partial sectional view of the support unit of the device for replacing idler rollers according to this utility model;

[0019] Figure 6 This invention relates to the working process of a device for replacing idler rollers. Detailed Implementation

[0020] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0021] To make the objectives, technical solutions, and advantages of this utility model clearer, the embodiments of this utility model will be further described in detail below with reference to specific examples and accompanying drawings.

[0022] In the description of this utility model, it should be understood that the terms "center", "length", "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model 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 utility model.

[0023] like Figure 1 As shown, this utility model discloses a device for replacing idler rollers, characterized in that it includes: an equipment base for providing stable support and installing a lifting unit; the equipment base includes two main beams 1, a battery compartment 12, and a control unit 13; the two main beams 1 are composed of two channel steels with openings facing inward, and each channel steel is symmetrically provided with a slide rail 11; the battery compartment 12 and the control unit 13 are respectively located at both ends of the two main beams 1.

[0024] like Figure 2 and Figure 3 As shown, the lifting unit is used to install the bearing unit and provide support for the bearing unit;

[0025] The lifting unit includes four first electric push rods 21, four moving sliders 22, two slider connecting shafts 23, and first transmission rods 241 and second transmission rods 242 arranged in a cross pattern.

[0026] The first electric push rod 21 is symmetrically fixed to the inner sidewalls of the slide rails 11 of the two main beams with bolts, with the centerline of the main beam 1 as the axis. The moving sliders 22 are hollow sliders with shaft holes, which are slidably engaged in the slide rails 11 of the two main beams. The telescopic ends of the first electric push rod 21 are provided with trunnion holes. The two moving sliders 22 corresponding to each other are hinged to the trunnion holes of the telescopic ends of the first electric push rod 21 through the slider connecting shaft 23. The first transmission rod is a straight rod 241, and the second transmission rod is designed with grooves. The shaft holes at the lower ends of the first transmission rod 241 and the second transmission rod 242 are hinged in the two main beams 1 through the slider connecting shaft 23. The telescopic movement of the telescopic end of the first electric push rod 21 drives the relative displacement of the moving sliders 22, thereby driving the first transmission rod 241 and the second transmission rod 242 to rise and fall.

[0027] like Figure 1 , 2 As shown in Figures 3, 4, and 5, the bearing unit is used to change the support length and support angle of the device, and the bearing unit is installed on the upper part of the lifting unit.

[0028] The bearing unit consists of a telescopic horizontal support mechanism 4 and a flip-type grooved support mechanism 3.

[0029] The telescopic horizontal support mechanism 4 includes a rectangular horizontal support frame I 41, a rectangular horizontal support frame II 42, and a second electric push rod 43. The rectangular horizontal support frame I 41 is a rectangular hollow steel section with openings at both ends. The horizontal support frame II 42 is a channel steel with an inwardly rolled edge and a smaller cross-sectional area than the horizontal support frame I, with the opening facing downwards. The horizontal support frame II 42 is inserted into the horizontal support frame I 41 and is slidably connected to it. The power end of the second electric push rod 43 is fixed to the rectangular horizontal support frame I 41 by bolts, and its telescopic end is connected to the right-side flip-type channel support mechanism 3. The left end is fixedly connected; trunnions 44 are respectively provided on the outer sides of both ends of the horizontal support frame I 41 and the horizontal support frame II 42, and a groove 45 matching the size of the trunnion is also opened at the open end of the horizontal support frame I 41. The upper ends of the first transmission rod 241 and the second transmission rod 242 of the lifting unit are respectively hinged to the trunnions 43 at both ends of the rectangular horizontal support frame I 41 and the horizontal support frame II 42; the horizontal support frame I and the horizontal support frame II are driven to move relative to each other by the telescopic movement of the second electric push rod 43 and the telescopic end of the first electric push rod 21, so that the length of the horizontal roller support part can be varied within the set range.

[0030] like Figure 5As shown, there are two flip-type grooved support mechanisms 3, symmetrically arranged at the left and right ends of the telescopic horizontal support mechanism 4. Each mechanism consists of a grooved support frame 31 with one closed end, a third electric push rod 32, an adjusting plate 34, pins A36, B37, and C35, and a grooved support plate. A shaft hole A311 and a sliding groove 312 are respectively opened on the frame of the grooved support frame 31. The third electric push rod 32 is fixedly installed on the bottom plate inside the grooved support frame 31 by bolts. The grooved support plate consists of an integrally formed upper cover plate 331 and two side plates 332. A shaft hole B is opened in the lower part of the side plates 332, and a lower shaft hole C is opened in the lower part. The adjusting plate 34 is positioned between the two side plates 332 at the top and inside the grooved support frame 31 at the bottom. An upper shaft hole and a lower shaft hole are respectively opened in the upper and lower parts of the adjusting plate 34. The closed end of the left grooved support frame 31 is bolted to the horizontal support frame 4. The left end of the first electric push rod 32 is fixedly connected, and the closed end of the right side groove support frame 31 is fixedly connected to the right end of the horizontal support frame II. A trunnion hole is provided at the telescopic end of the third electric push rod 32. The pin A36 passes through the slide groove A312, the lower shaft hole of the adjusting plate 34, and the trunnion hole at the telescopic end of the third electric push rod 32, respectively, hinged to the telescopic end of the third electric push rod 32 and the lower end of the adjusting plate 34 within the groove support frame 31. The pin B37 passes through the groove support... The shaft holes B in the lower part of the two side plates 332 and the upper shaft hole of the adjusting plate hinge the upper end of the adjusting plate 34 to the lower part of the two side plates 332; the pins C35 pass through the shaft holes A311 on the frame of the slotted support frame and the shaft holes C in the lower part of the two side plates 332 respectively, and hinge the lower part of the slotted support plate to the slotted support frame 31; the extension and retraction of the third electric push rod 32 can drive the adjusting plate 34 to deflect, thereby adjusting the flip angle of the slotted support plate.

[0031] The power supply lines of the first type of electric actuator 21, the second type of electric actuator 43, and the third type of electric actuator 32 are all connected to the lithium iron phosphate battery in the battery compartment 12; the control lines are respectively connected to their respective servo motor drivers in the control unit 13, and the operation is completed by controlling the servo motor drivers through the control unit.

[0032] In use, the replacement of idlers can be completed by a single person. During operation, firstly, the two main beams 11 are placed on the intermediate frame between the idler to be replaced and its adjacent idlers on the belt conveyor. Then, one person simultaneously controls the extension of the second electric push rod 43 and the retraction of the first electric push rod 21 via the operation control unit 13. The extension of the second electric push rod 43 causes the horizontal support frame II 42 to extend from the horizontal support frame I 41. The retraction of the first electric push rod 21 drives the first transmission rod 241 and the second transmission rod 242 to move up and down synchronously with the horizontal support frame II 42 and the horizontal support frame I 41, thereby adjusting the horizontal idler support to the required length. Then, the third electric push rod 32 is controlled to adjust the trough support frame 3 to the required angle. Finally, the retraction of the first electric push rod 21 is controlled separately, driving the first transmission rod 241 and the second transmission rod 242 to rise and fall, raising the carrying unit and lifting the conveyor belt above the idler to a certain height. Figure 6 As shown, the idler roller is finally removed and replaced; after the idler roller is replaced, the third electric push rod 32 adjusts the trough support frame 3 to a horizontal state; the first electric push rod 21 extends, driving the first transmission rod 241 and the second transmission rod 242 to descend, causing the bearing unit to descend. Figure 1 Status; the first electric push rod 21 continues to extend, driving the first transmission rod 241 and the second transmission rod 242 to move, while the second electric push rod 43 retracts, causing the horizontal support frame II 42 I 41 to fully retract into the horizontal support frame I 41; the unloading of the equipment is completed. Figure 1 The device shown is not in operation.

[0033] In use, the entire support process of this invention is controlled by the control unit, eliminating the need for manual operation. It provides strong support, allowing a single person to carry the material and change the idler rollers. This improves safety and significantly reduces the time and labor costs associated with equipment maintenance and repair, demonstrating substantial economic value. The control unit of this invention is existing technology and will not be described in detail here.

[0034] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the present invention (including the claims) is limited to these examples. Within the framework of the present invention, technical features of the above embodiments or different embodiments can also be combined, and many other variations of different aspects of the present invention exist, which are not provided in the details for the sake of brevity. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A device for replacing idler rollers, characterized in that, include: Equipment base, used to provide stable support and install lifting units; The lifting unit is used to install the load-bearing unit and provide support for the load-bearing unit; The lifting unit includes four first electric push rods, four moving sliders, two slider connecting shafts, and a pair of first and second transmission rods arranged in a cross configuration. The first electric push rod is symmetrically fixed to the inner sidewalls of the slide rails of the two main beams by bolts, with the centerline of the two main beams as the axis. The moving slider is a hollow slider with a shaft hole, which is slidably engaged in the slide rails of the two main beams. The telescopic end of the first electric push rod is provided with a trunnion hole, and the two corresponding moving sliders are hinged to the trunnion hole of the telescopic end of the first electric push rod through the slider connecting shaft. The first transmission rod is a straight rod, and the second transmission rod is a straight rod with a groove in the middle. The upper and lower ends of the first and second transmission rods are respectively provided with shaft holes. The shaft holes at the lower ends of the first and second transmission rods are hinged in the two main beams through the slider connecting shaft. A support unit is used to change the support length and support angle of the device, and the support unit is installed on the upper part of the lifting unit.

2. The device for replacing idler rollers according to claim 1, characterized in that, The equipment base includes two main beams, a battery compartment, and a control unit. The two main beams are composed of two inward-opening channel steels, with symmetrical sliding tracks provided in each channel steel. The battery compartment and the control unit are respectively located at both ends of the two main beams.

3. The device for replacing idler rollers according to claim 1, characterized in that, The load-bearing unit consists of a telescopic horizontal support mechanism and a tilting groove-type support mechanism. The telescopic horizontal support mechanism includes a rectangular horizontal support frame I, a rectangular horizontal support frame II, and a second electric push rod. The rectangular horizontal support frame I is a rectangular hollow steel section with openings at both ends. The horizontal support frame II is an inwardly rolled channel steel with a cross-sectional area smaller than that of the horizontal support frame I and an opening facing downwards. The horizontal support frame II is inserted into the horizontal support frame I and is slidably connected to it. The power end of the second electric push rod is fixed to the rectangular horizontal support frame I with bolts, and its telescopic end is fixedly connected to the left end of the right-side flip-type channel support mechanism. Trunnions are provided on the outer sides of both ends of the horizontal support frame I and the horizontal support frame II. A groove matching the size of the trunnion is also provided at the open end of the horizontal support frame I. The upper ends of the first and second transmission rods of the lifting unit are respectively hinged to the trunnions at both ends of the rectangular horizontal support frame I and the horizontal support frame II. Two flip-type grooved support mechanisms are symmetrically arranged at the left and right ends of the telescopic horizontal support mechanism. Each mechanism consists of a grooved support frame with one closed end, a third electric push rod, an adjusting plate, pins A, B, and C, and a grooved support plate. A shaft hole A and a sliding groove are respectively opened on the frame of the grooved support frame. The second electric push rod is bolted to the base plate inside the grooved support frame. The grooved support plate consists of an integrally formed upper cover plate and two side plates. A shaft hole B is opened in the lower part of the side plates, and a lower shaft hole C is opened in the lower part. The adjusting plate is located between the grooved support frame and the side plates. An upper shaft hole and a lower shaft hole are respectively opened in the upper and lower parts of the adjusting plate. The left grooved support frame... The closed end is fixedly connected to the left end of the horizontal support frame I, and the closed end of the right-side channel support frame is fixedly connected to the right end of the horizontal support frame II. The telescopic end of the second electric push rod is provided with a trunnion hole. The pin A passes through the slide groove A, the lower shaft hole of the adjusting plate, and the trunnion hole of the telescopic end of the second electric push rod, respectively, and hinges the telescopic end of the second electric push rod and the lower end of the adjusting plate in the channel support frame. The pin B passes through the shaft hole B opened in the lower middle part of the two side plates of the channel support plate and the upper shaft hole of the adjusting plate, respectively, and hinges the upper end of the adjusting plate to the lower middle part of the two side plates. The pin C passes through the shaft hole A opened on the frame of the channel support frame and the shaft hole C opened in the lower part of the two side plates, respectively, and hinges the lower part of the channel support plate in the channel support frame.

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