Lightweight self-lubricating cable supporting wheel device

Abstract

The utility model provides a lightweight self-lubricating cable supporting wheel device, which integrates material modification, structure innovation and lubrication optimization, realizes the collaborative breakthrough of friction coefficient reduction, self-lubrication, light weight and convenient maintenance on the premise of ensuring the bearing reliability, and comprises a wheel core and a wheel lining, the center of the wheel core is coaxially fixed to the wheel axle, and an assembly ring groove is formed in the outer ring side of the wheel core. The wheel lining is a pp modified base body, is assembled in the assembling ring groove in an interference fit mode and wraps the periphery of the wheel core, the section of the wheel lining is in a fishtail shape, a first arc-shaped groove and a second arc-shaped groove which are sequentially formed from outside to inside are formed in the outer ring side of the wheel lining, and the diameter of the second arc-shaped groove is smaller than that of the first arc-shaped groove. The distance between the bottom face of the second arc-shaped groove and the wheel core is smaller than that between the bottom face of the first arc-shaped groove and the wheel core, and the friction coefficient of the contact faces of the first arc-shaped groove and the second arc-shaped groove and the steel wire rope is smaller than or equal to 0.15.

Description

Technical Field

[0001] This utility model relates to the field of cableway transportation, and more specifically, to a lightweight self-lubricating cable wheel device. Background Technology

[0002] In wire rope drive systems such as passenger ropeways and port cranes, the cable pulley serves as a critical guiding component, and its performance directly affects the equipment's operating efficiency and safety. Traditional cable pulleys generally employ a one-piece cast aluminum wheel structure, which has the following technical drawbacks:

[0003] 1. Material limitations: The aluminum rope groove (friction coefficient 0.3-0.5) experiences severe dry friction with the steel wire rope, accelerating groove wear (annual wear of 3-5mm), resulting in a steel wire rope service life of less than 12 months. Although external grease lubrication is used, the grease easily attracts dust, forming abrasive wear, and the annual maintenance cost is as high as 25% of the total equipment cost.

[0004] 2. Structural design flaws: The single arc-shaped rope groove leads to stress concentration (local contact pressure > 80MPa) and lacks a wear compensation mechanism. When the rope groove depth wear exceeds 2mm, the entire rope needs to be replaced. The cast aluminum wheel body has a density of 2.7g / cm³, and a typical Φ600mm cable pulley weighs 24kg, exacerbating rotational inertia and support load.

[0005] 3. Inefficient lubrication system: Traditional gaskets are prone to grease leakage, requiring manual grease replenishment weekly, and lack precise oil quantity control, resulting in over 50% lubricant waste. The use of fixed washers in bearing assembly cannot compensate for axial wear, leading to premature bearing failure. Utility Model Content

[0006] The purpose of this utility model is to provide a lightweight self-lubricating cable roller device that integrates material modification, structural innovation and lubrication optimization. Under the premise of ensuring load-bearing reliability, it achieves a synergistic breakthrough in reducing the coefficient of friction, self-lubrication, lightweighting and convenient maintenance.

[0007] The embodiments of this utility model are implemented as follows:

[0008] A lightweight self-lubricating cable pulley device includes a wheel core and a wheel bushing. The wheel core is coaxially fixed to the wheel axle, and an assembly ring groove is provided on the outer ring side of the wheel core. The wheel bushing is made of modified PP matrix and is assembled into the assembly ring groove by interference fit, covering the outer circumference of the wheel core. The cross-section of the wheel bushing is fishtail shaped. A first arc-shaped groove and a second arc-shaped groove are provided on the outer ring side of the wheel bushing from the outside to the inside. The diameter of the second arc-shaped groove is smaller than the diameter of the first arc-shaped groove, and the distance from the bottom surface of the second arc-shaped groove to the wheel core is smaller than the distance from the bottom surface of the first arc-shaped groove to the wheel core. The coefficient of friction between the first arc-shaped groove and the contact surface of the second arc-shaped groove and the wire rope is ≤0.15.

[0009] In a preferred embodiment of the present invention, a self-lubricating assembly is assembled between the wheel axle and the wheel core. The self-lubricating assembly includes a bearing cap, a sealing ring, a bearing, and a lubrication adjustment ring symmetrically arranged on the wheel axle from the outside to the inside.

[0010] In a preferred embodiment of this utility model, the bearing cap and the wheel core are connected by a second bolt group, and a single-ear stop washer is provided on the axial movement path of the second bolt group.

[0011] In a preferred embodiment of this utility model, a labyrinth seal structure is provided between the bearing cover and the sealing ring.

[0012] In a preferred embodiment of the present invention, the above-mentioned cable pulley device further includes an annular wheel side plate, which is fastened to both sides of the wheel core by a first bolt group to form an annular weight reduction groove; the shape of the wheel side plate matches the shape of the wheel liner, protecting the wheel liner inside.

[0013] In a preferred embodiment of this utility model, the wheel side plate is forged from 7075 aluminum alloy, and its outer edge thickness is 1.2-1.5 times that of the middle thickness, and a shock-absorbing rubber edging is provided at the outer edge.

[0014] In a preferred embodiment of the present invention, a first lubrication cavity exists between the lubrication adjusting ring and the wheel axle, and a second lubrication cavity exists between the lubrication adjusting ring and the wheel core.

[0015] In a preferred embodiment of this utility model, the interference fit between the wheel bushing and the wheel core is 0.03%-0.05% of the fitting diameter.

[0016] In a preferred embodiment of the present invention, the surface of the above-mentioned lubrication adjustment ring is provided with a spiral oil guide groove, the depth of the oil guide groove is 0.5-0.8mm, the spiral helix angle is 15°-25°, and the end of the oil guide groove extends to the bearing.

[0017] In a preferred embodiment of the present invention, the bottom layer of the above-mentioned PP modified matrix is ​​a carbon fiber reinforced layer with a tensile strength ≥50 MPa; the middle layer is a wear-resistant layer containing nano-alumina with a Rockwell hardness ≥85 HRR; and the surface layer is a 100% pure PP modified layer with a friction coefficient ≤0.15.

[0018] The beneficial effects of this utility model embodiment are:

[0019] 1. A wheel liner is installed on the wheel core. The wheel liner is made of PP modified matrix, which significantly reduces the coefficient of friction compared with traditional aluminum rope groove. The material itself contains solid lubricant (such as molybdenum disulfide), which realizes oil-free self-lubrication and avoids the problem of environmental pollution caused by traditional grease.

[0020] 2. Replacing the original aluminum wheel with a ring-shaped wheel side plate and wheel liner can reduce the weight of the cable wheel while also ensuring the stability of the device.

[0021] 3. The wheel liner adopts a fishtail section and double arc groove topology optimization. The diameter of the first arc groove (main load-bearing area) is larger than that of the second arc groove (auxiliary guide area), forming a progressive load transfer path, which reduces the peak contact pressure of the wire rope by 40% and effectively avoids rope groove cracking caused by stress concentration. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic cross-sectional view of the lightweight self-lubricating cable pulley device according to an embodiment of the present invention;

[0024] Figure 2 This is a side view of the lightweight self-lubricating cable pulley device according to an embodiment of the present invention;

[0025] Figure 3 This is an enlarged structural schematic diagram of the location of the self-lubricating component in an embodiment of the present invention;

[0026] Figure 4 This is a schematic diagram of the functional layers of the wheel liner according to an embodiment of the present invention;

[0027] Icons: Wheel axle 110; First flat washer 111; First nut 112; Wheel core 120; Wheel axle mounting hole 121; Bearing cap mounting hole 122; Wheel side plate mounting hole 123; Second bolt group 124; First bolt group 125; Single-ear retaining washer 126; Mounting ring groove 127; Wheel liner 130; Carbon fiber reinforcement layer 131; Wear-resistant layer 132; PP modified layer 133; First arc groove 134; Second arc groove 135; Wheel side plate 140; Self-lubricating component 150; Bearing cap 151; Sealing ring 152; Bearing 153; Lubrication adjustment ring 154; Labyrinth seal structure 155; First lubrication chamber 156; Second lubrication chamber 157. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0029] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0030] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0031] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this utility model is in use. 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. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0032] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0033] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" 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 of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0034] First Embodiment

[0035] Please refer to Figure 1-4 This embodiment provides a lightweight self-lubricating cable pulley device, including a wheel axle 110, a wheel core 120 coaxially fixed on the wheel axle 110, a wheel bushing 130 assembled outside the wheel core 120, annular wheel side plates 140 assembled on both sides of the wheel core 120 and used to constrain the wheel bushing 130, and a self-lubricating component 150 disposed between the wheel axle 110 and the wheel core 120.

[0036] The end of the wheel axle 110 is positioned by a first flat washer 111 and a first nut 112. The wheel core 120 has a wheel axle mounting hole 121 at its center. Bearing cap mounting holes 122 and wheel side plate mounting holes 123 are sequentially arranged outwards from the wheel axle mounting hole 121. A second bolt group 124 is inserted into the corresponding through holes of the bearing cap and the bearing cap mounting hole 122 to fix the bearing cap to the wheel core 120. A first bolt group 125 is inserted into the corresponding through holes of the wheel side plate 140 and the wheel side plate mounting hole 123 to fix the wheel side plate 140 to the wheel core 120. The first bolt group 125 consists of a bolt, a nut, and a single-eared locking washer 126; the second bolt group 124 consists of a bolt, a nut, and a flat washer.

[0037] Specifically, in this embodiment, four bearing cap mounting holes 122 and wheel side plate mounting holes 123 are provided and are distributed in a staggered ring array to reduce stress concentration. The wheel core 120 is coaxially fixed to the wheel axle 110, and the outer ring side of the wheel core 120 is provided with a mounting ring groove 127 to facilitate the assembly of the wheel bushing 130. The interior of the wheel core 120 can also be made of hollow honeycomb aluminum to further reduce the weight of the cable pulley.

[0038] A self-lubricating assembly 150 is assembled between the wheel core 120 and the wheel axle 110. The self-lubricating assembly 150 includes a bearing cap 151, a sealing ring 152, a bearing 153, and a lubrication adjustment ring 154 symmetrically arranged from the outside to the inside on the wheel axle 110. A labyrinth seal structure 155 is provided between the bearing cap 151 and the sealing ring 152.

[0039] A first lubrication chamber 156 exists between the lubrication adjusting ring 154 and the wheel axle 110, and a second lubrication chamber 157 exists between the lubrication adjusting ring 154 and the wheel core 120. The surface of the lubrication adjusting ring 154 is provided with a spiral oil guide groove, the groove depth being 0.5-0.8 mm and the spiral helix angle being 15°-25°. The end of the oil guide groove extends to the bearing 153, improving lubrication utilization. Through precise ±0.2 mm displacement control of the adjusting ring, in conjunction with the labyrinth seal ring 152, continuous grease supply and dynamic sealing are achieved.

[0040] The wheel side plate 140 is fastened to both sides of the wheel core 120 by the first bolt group 125, forming an annular weight-reducing groove 141. The wheel core and the wheel side plate 140 have a stepped transition structure, reducing the maximum equivalent stress and thus extending the service life. The shape of the wheel side plate 140 matches the shape of the wheel liner 130, protecting the wheel liner 130 inside. The wheel side plate 140 is forged from 7075 aluminum alloy, and its outer edge thickness is 1.2-1.5 times the middle thickness, and a shock-absorbing rubber edging is provided at the outer edge. Compared with the original aluminum wheel, the wheel side plate 140 in this embodiment can maintain the wheel shape and protect the internal wheel liner 130.

[0041] The wheel liner 130 is made of modified PP matrix, with 5-8 wt% nano-alumina and 10-15 mm long, 3-5 wt% short carbon fiber filaments added. The bottom layer of the modified PP matrix is ​​a carbon fiber reinforcement layer 131 with a tensile strength ≥50 MPa; the middle layer is a wear-resistant layer 132 containing nano-alumina with a Rockwell hardness ≥85 HRR; and the surface layer is a 100% pure PP modified layer 133 with a coefficient of friction ≤0.15. By using modified polypropylene (PP) composite material to replace the traditional aluminum rope groove, the coefficient of friction is reduced from 0.3-0.5 of aluminum to ≤0.15, a reduction of 50%-70%. The material itself contains solid lubricants, such as molybdenum disulfide, achieving oil-free self-lubrication and avoiding the environmental pollution problems caused by traditional greases.

[0042] The wheel liner 130 is assembled to the assembly ring groove 127 by interference fit, the interference fit amount is 0.03%-0.05% of the fitting diameter, and covers the outer circumference of the wheel core 120. The cross-section of the wheel liner 130 is fishtail shaped. The outer ring side of the wheel liner 130 is provided with a first arc groove 134 and a second arc groove 135 arranged sequentially from the outside to the inside. The diameter of the second arc groove 135 is smaller than the diameter of the first arc groove 134, and the distance from the bottom surface of the second arc groove 135 to the wheel core 120 is smaller than the distance from the bottom surface of the first arc groove 134 to the wheel core 120. The coefficient of friction between the first arc groove 134 and the second arc groove 135 and the contact surface with the wire rope is ≤0.15.

[0043] Furthermore, an intelligent lubrication feedback device can be installed at the wheel liner 130 position. For example, a piezoelectric wear sensor with a detection accuracy of ±5μm can be installed in the second arc groove 135 to monitor the change in rope groove thickness in real time. A matching micro metering pump (flow rate 0.1-0.5ml / min) automatically replenishes grease through capillary oil channels. The oil circuit system is equipped with a PID temperature control module (operating temperature range -20℃~80℃).

[0044] This specification describes examples of embodiments of the present invention, but does not imply that these embodiments illustrate and describe all possible forms of the present invention. It should be understood that the embodiments in the specification can be implemented in various alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or reduced to show details of specific components. The specific structural and functional details disclosed should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to implement the present invention in various forms. Those skilled in the art will understand that multiple features illustrated and described with reference to any of the drawings can be combined with features illustrated in one or more other drawings to form embodiments not explicitly illustrated or described. The illustrated combinations of features provide representative embodiments for typical applications. However, various combinations and variations of features consistent with the teachings of the present invention may be used as needed for specific applications or implementations.

[0045] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A lightweight self-lubricating cable pulley device, characterized in that, include: The wheel core is coaxially fixed to the wheel axle, and an assembly ring groove is provided on the outer ring side of the wheel core; The wheel liner, made of modified PP matrix, is assembled to the mounting ring groove by interference fit and covers the outer periphery of the wheel core. The wheel liner has a fishtail-shaped cross-section. The outer ring side of the wheel liner is provided with a first arc-shaped groove and a second arc-shaped groove arranged sequentially from the outside to the inside. The diameter of the second arc-shaped groove is smaller than the diameter of the first arc-shaped groove, and the distance from the bottom surface of the second arc-shaped groove to the wheel core is smaller than the distance from the bottom surface of the second arc-shaped groove to the wheel core. The coefficient of friction between the first arc-shaped groove and the second arc-shaped groove and the contact surface with the wire rope is ≤0.

15.

2. The lightweight self-lubricating roller device according to claim 1, characterized in that, A self-lubricating assembly is assembled between the wheel axle and the wheel core. The self-lubricating assembly includes a bearing cap, a sealing ring, a bearing, and a lubrication adjustment ring symmetrically arranged from the outside to the inside on the wheel axle.

3. The lightweight self-lubricating cable pulley device according to claim 2, characterized in that, The bearing cap and the wheel core are connected by a second bolt group, and a single-ear stop washer is provided on the axial movement path of the second bolt group.

4. The lightweight self-lubricating roller device according to claim 2, characterized in that, A labyrinth seal structure is provided between the bearing cap and the sealing ring.

5. The lightweight self-lubricating roller device according to claim 1, characterized in that, The cable pulley device also includes an annular wheel side plate, which is fastened to both sides of the wheel core by a first bolt group to form an annular weight reduction groove; the shape of the wheel side plate matches the shape of the wheel liner, protecting the wheel liner inside.

6. The lightweight self-lubricating roller device according to claim 5, characterized in that, The wheel side plate is forged from 7075 aluminum alloy, with an outer edge thickness of 1.2-1.5 times that of the middle edge, and a shock-absorbing rubber edging is provided at the outer edge.

7. The lightweight self-lubricating roller device according to claim 2, characterized in that, A first lubrication cavity exists between the lubrication adjusting ring and the wheel axle, and a second lubrication cavity exists between the lubrication adjusting ring and the wheel core.

8. The lightweight self-lubricating roller device according to claim 1, characterized in that, The interference fit between the wheel liner and the wheel core is 0.03%-0.05% of the fitting diameter.

9. The lightweight self-lubricating roller device according to claim 2, characterized in that, The surface of the lubrication adjustment ring is provided with a spiral oil guide groove, the depth of which is 0.5-0.8mm and the spiral helix angle is 15°-25°. The end of the oil guide groove extends to the bearing.

10. The lightweight self-lubricating roller device according to any one of claims 1-9, characterized in that, The bottom layer of the PP modified matrix is ​​a carbon fiber reinforced layer with a tensile strength ≥50 MPa; the middle layer is a wear-resistant layer containing nano-alumina with a Rockwell hardness ≥85 HRR; and the surface layer is a 100% pure PP modified layer with a coefficient of friction ≤0.15.

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