A conveyor belt hanging idler roller replacement device

Abstract

This utility model discloses a conveyor belt idler replacement device, including a conveyor frame, idlers, and a replacement mechanism. The conveyor is equipped with idlers, and the replacement mechanism, which connects to the hanging chains on the idlers, is mounted on the side frame of each idler. The replacement mechanism also includes a mounting base for positioning and support on the frame, a handle for extending the working stroke and acting as a fulcrum, a safety chain, and a lever hoist as a power source. The function of this utility model is to remove damaged idlers from the conveyor and install new ones, achieving rapid replacement of conveyor idlers. This tool saves manpower, is highly applicable, and easy to operate. It improves the efficiency of idler disassembly and installation, ensuring continuous production.

Description

Technical Field

[0001] This utility model patent belongs to the technical field of conveyor belt maintenance equipment, specifically relating to a conveyor belt hanging idler replacement device. Background Technology

[0002] Mining conveyors are typically used to transport stripped waste rock or mined ore. In medium to large open-pit mines, due to the large volume of waste rock or ore to be transported, conveyors with high transport capacity and high operating speeds are often used. This results in high impact force from the material conveyed at the conveyor ends, and the impact point has a wide stress surface, leading to frequent equipment failures. Ensuring the normal operation of belt conveyors is a crucial daily maintenance task. For long-distance belt conveyors, early detection of idler abnormalities and timely replacement of damaged idlers are among the most common and critical maintenance tasks.

[0003] Replacing idlers is inconvenient due to limitations in on-site working conditions, generally requiring at least 4 to 5 people to complete the replacement. For movable conveyor belts with suspended upper, parallel, and lower idlers, jacks and lever hoists are also needed. To facilitate replacement and operations, technicians have made several attempts to modify the replacement tools, but with limited success. This is particularly true for repairing lower idlers, which requires personnel to crawl under the conveyor belt's working surface, creating a space where idlers can easily fall and cause injury. While existing technologies, such as Chinese patent (CN222974808U), disclose a lifting device for quick replacement of belt conveyor idlers, this device has a significant drawback: it needs to be placed under the belt conveyor. However, in reality, the bottom of belt conveyors in mines is very close to the ground. Placing such a large device inside significantly reduces the actual operating space, making maintenance difficult.

[0004] Therefore, this paper proposes a conveyor belt hanging idler replacement device. Utility Model Content

[0005] To address the aforementioned problems, this utility model aims to provide a conveyor belt idler replacement device. This device allows for the removal of damaged idlers and the installation of new ones, achieving rapid replacement of conveyor idlers. This tool saves manpower, is highly applicable, and easy to operate, significantly improving the efficiency of idler removal and installation. Previously, it required 4-5 people and 20 minutes; now, only 2 people are needed in 3 minutes to remove the damaged idler and install the new one, ensuring continuous production. Furthermore, this tool eliminates safety hazards. Normally, when idlers are damaged, maintenance personnel need to crawl under the conveyor belt to replace them, posing a safety risk of injury to feet and hands. Now, workers can replace idlers without crawling under the conveyor belt, ensuring personnel safety.

[0006] This utility model is achieved through the following technical solution: a conveyor belt hanging idler replacement device, including a conveyor frame, hanging idlers, and a replacement mechanism. The conveyor is equipped with hanging idlers, and a replacement mechanism that can be connected to the hanging iron chain on the hanging idler is installed on the side frame of the hanging idler. The replacement mechanism also includes a clamping base that can be positioned and supported on the frame, a handle that can extend the working stroke and act as a fulcrum, a safety protection iron chain, and a lever hoist as a power source. The end of the handle is installed on the upper side of the clamping base, the middle of the handle is connected to the lower end of the safety protection iron chain, and the upper end of the safety protection iron chain is connected to the frame through a hook. The top housing hook A of the lever hoist is engaged with the through hole at the front end of the handle, and the lower end of the lever hoist is connected to the hanging iron chain on the hanging idler through the hook B at the end of the chain.

[0007] Preferably, the mounting base has an opening on its lower side that is the same width as the cross-section of the frame.

[0008] Preferably, the installation method of the handle end and the upper side of the mounting base also includes welding, threaded connection, and hinge limiting structure connection with adjustable rotation angle.

[0009] Preferably, the end of the handle is connected to the upper side of the mounting base by welding, and the opening direction of the mounting base forms an angle of 110° to 130° with the axial direction of the handle.

[0010] Preferably, the end of the handle is connected to the upper side of the mounting base by a threaded structure. The threaded structure also includes a threaded sleeve welded to the side of the mounting base and a threaded rod located at the end of the handle. The opening direction of the mounting base forms an angle of 110° to 130° with the axial direction of the handle.

[0011] Preferably, the handle end is connected to the upper side of the mounting base using an adjustable hinge limiting structure. The hinge limiting structure further includes a hinge support A, a slide groove, a hinge support B, a support plate, a shaft, and a locking nut. The hinge support A is located at the upper rear end of the mounting base and is rotatably connected to the handle end via a hinge structure. A slide groove is provided on the upper side of the mounting base in front of the hinge support A. The hinge support B is slidably installed in the slide groove via a shaft and can be positioned in the slide groove by tightening the locking nuts at both ends of the shaft. A support plate that is longer at the front and shorter at the back is rotatably installed on the hinge support B via a hinge structure.

[0012] The beneficial effects of this utility model are:

[0013] 1. This utility model designs and manufactures a replacement device for hanging idler rollers of a mining conveyor, which can save manpower, has strong applicability, is easy to operate, and improves the efficiency of disassembling idler rollers. Previously, it required 4-5 people to operate for 20 minutes, but now only 2 people can operate for 3 minutes to remove the damaged idler roller and install the new idler roller. The replacement device can ensure the continuity of production and avoid production interruption and economic losses caused by long-term downtime.

[0014] 2. This replacement device can eliminate safety hazards at the source. Normally, when the suspended idler is damaged, maintenance personnel need to crawl under the conveyor belt to replace the idler, which poses a safety hazard and can easily cause injury to feet or hands. Now, the operators can replace the suspended idler without crawling under the conveyor belt, ensuring the safety of personnel.

[0015] 3. With the use of the hanging idler replacement device, when removing and installing idlers, two operators can lift the 150kg idler set (3 sets) without entering the narrow working space of the lower conveyor belt. After the improvement, the idler set can be easily removed and installed with just a little force through the replacement mechanism.

[0016] 4. Before the improvement, only wire ropes and hand chain hoists could be used to replace idler rollers. The spatial relationship between the hand chain hoist and the idler roller chain was perpendicular, and the travel distance was insufficient, making it difficult to replace the idler rollers. After the improvement, the hand chain hoist can be directly pulled onto the idler roller replacement device. Because the spatial relationship between the hand chain hoist and the idler roller chain is parallel, the travel distance is sufficient, making it easy to replace the idler rollers. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this utility model, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0018] Figure 1 This is a left view of the application scenario of the hanging idler roller of this utility model;

[0019] Figure 2 This is a front view of the application scenario of this utility model;

[0020] Figure 3 This is a structural diagram of embodiment 3 of the present invention, which uses a threaded connection.

[0021] Figure 4 This utility model Figure 3 An isometric sectional view of the internal structure.

[0022] Figure 5 This is a partial schematic diagram of A in component 4 of this utility model;

[0023] Figure 6 This is an isometric view of the structure of Embodiment 4 of this utility model, which uses a hinge limiting structure for connection.

[0024] Figure 7 This is a cross-sectional view of the front view of Embodiment 4 of the present invention, which uses a hinge limiting structure for connection.

[0025] The attached diagram lists the components represented by each number as follows:

[0026] 1. Conveyor frame; 2. Suspended idler roller; 3. Suspended chain; 4. Mounting base; 5. Handle; 6. Safety chain; 7. Lever hoist; 8. Opening; 9. Screw sleeve; 10. Screw; 11. Hinge support A; 12. Slide groove; 13. Hinge support B; 14. Pallet; 15. Lifting lug washer; 16. Hook; 17. Lifting hook A

[0027] 18. Hook B; 19. Shaft; 20. Locking nut. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the scope of protection of the present utility model. Example 1

[0029] like Figures 1 to 2 As shown, the existing technology in this embodiment has the following problems: The inventors found that due to the limitations of on-site working conditions, replacing idlers is inconvenient, generally requiring at least 4 to 5 people to complete the replacement. For the upper, parallel, and lower idlers of the portable conveyor belt, tools such as jacks and lever hoists are also required. To facilitate replacement and operation, technicians have tried to modify the replacement tools many times, but the results have been unsatisfactory. In particular, for the maintenance of the lower idlers, it is necessary for people to crawl under the working surface of the conveyor belt to replace the idlers, but the space is limited and the idlers are prone to falling and injuring people. Although the existing technology, such as Chinese Patent (CN222974808U), discloses a lifting device for quick replacement of belt conveyor idlers, this device has obvious defects. That is, its lifting device needs to be placed under the belt conveyor. However, in reality, the bottom of the belt conveyor in the mine is very close to the ground. After such a large structure of the device is placed inside, the actual operating space becomes very small, which is also inconvenient for maintenance personnel to carry out maintenance.

[0030] Therefore, the inventor provides a conveyor belt hanging idler roller 2 replacement device, including a conveyor frame 1, a hanging idler roller 2, and a replacement mechanism. The hanging idler roller 2 is installed on the conveyor. The replacement mechanism, which can be connected to the hanging iron chain 3 on the hanging idler roller 2, is installed on the side frame of the hanging idler roller 2. The replacement mechanism also includes a clamping base 4 that can be positioned and supported on the frame, a handle 5 that can extend the working stroke and act as a fulcrum, a safety protection iron chain 6, and a lever hoist 7 as a power source. The end of the handle 5 is installed on the upper side of the clamping base 4. The lower end of the safety protection iron chain 6 is connected to the middle of the handle 5, and the upper end of the safety protection iron chain 6 is connected to the frame through a hook 16. The top housing hook A17 of the lever hoist 7 is engaged with the through hole at the front end of the handle 5. The lower end of the lever hoist 7 is connected to the hanging iron chain 3 on the hanging idler roller 2 through a hook B18 at the end of the chain.

[0031] Furthermore, the mounting base 4 has an opening 8 on its lower side that is the same width as the cross-section of the frame; the basic function of this structure is to provide a clamping part that is compatible with the channel steel of the conveyor frame 1, so as to realize the installation and removal of the hanging roller 2 by applying external force.

[0032] Furthermore, the installation methods of the end of the handle 5 and the upper side of the mounting base 4 also include welding, threaded connection, and hinge limit structure connection with adjustable rotation angle. The welding and threaded connection methods require that the angle between the opening 8 of the mounting base 4 and the axis of the handle 5 be machined in one go to ensure the transmission effect of the tension. At the same time, the threaded connection can extend the service life of the unreplaced structure. The hinge limit structure connection with adjustable rotation angle can make it easy for the user to adjust the angle between the opening 8 of the mounting base 4 and the axis of the handle 5, thereby making it easy to adjust the direction of the tension under different application conditions (such as obstructions on the frame). Example 2

[0033] like Figure 2 As shown, based on the above embodiment, the end of the handle 5 is connected to the upper side of the mounting base 4 by welding. The opening 8 of the mounting base 4 forms an angle of 110° to 130° with the axis of the handle 5. This structure makes the traction direction of the hand chain hoist and the spatial position and movement direction of the idler chain tend to be parallel, thereby ensuring sufficient stroke distance, more stable and effective transmission of tension, and easy replacement of the idler. Example 3

[0034] like Figures 3 to 5As shown in the above embodiment, the end of the handle 5 is connected to the upper side of the mounting base 4 by a threaded structure. The threaded structure also includes a threaded sleeve 9 welded to the side of the mounting base 4 and a screw 10 located at the end of the handle 5. The opening 8 of the mounting base 4 forms an angle of 110° to 130° with the axial direction of the handle 5. While ensuring the transmission of tension, this structure is also designed so that the front end of the handle 5 serves as the hook A engagement point. After long-term use, the front end of the handle 5 may be damaged. If continued use is made, it is easy to disengage and cause a safety accident. The same applies to the mounting base 4. Therefore, by adopting a detachable and replaceable threaded structure, the handle 5 or the mounting base 4 can be replaced at will according to the usage, extending the service life of the unreplaced structure. Both have low processing costs and are easy to carry. Example 4

[0035] like Figures 6 to 7 As shown in the above embodiment, the end of the handle 5 is connected to the upper side of the mounting base 4 using an adjustable hinge limiting structure. The hinge limiting structure further includes a hinge support A11, a slide groove 12, a hinge support B13, a support plate 14, a shaft 19, and a locking nut 20. The hinge support A11 is located at the upper rear end of the mounting base 4 and is rotatably connected to the end of the handle 5 via a hinge structure. A slide groove 12 is provided on the upper side of the mounting base 4 in front of the hinge support A11. The hinge support B13 slides via the shaft 19. The hinge support B13 is installed in the slide groove 12 and can be positioned in the slide groove 12 by tightening the locking nuts 20 at both ends of the shaft 19. The hinge support B13 is rotatably mounted with a front-long and rear-short support plate 14 through the hinge structure. The design of this structure makes it convenient for maintenance personnel to change the angle between the axis of the handle 5 and the direction of the opening 8 of the clamping base 4 by adjusting the position of the hinge support B13 in the slide groove 12 when encountering complex environments such as obstructions on the frame. The front-long and rear-short support plate 14 on the hinge support B13 can provide support for the handle 5. Example 5

[0036] Based on the above technical solution, the inventors have implemented it in practice, and the structural selections are as follows, wherein the handle 5 and the mounting base 4 are assembled by welding:

[0037] 1. The overall length of the device needs to be determined based on the distance of the hanging roller 2 on the frame during inspection and maintenance. The hanging chain 3 of each hanging roller 2 needs to be pulled out 5 rings using special tools, and the lifting lug 15 is locked in the 4th ring for positioning.

[0038] 2. The clamping base 4 is a clamping part that is compatible with the channel steel of the conveyor frame 1. It is made of Q235 steel plate welded to the center of the longitudinal axis of the head of the seamless steel pipe handle 5. The connection between the seamless steel pipe handle 5 and the clamping base 4 uses triangular steel plate as rib to enhance strength and prevent deformation during use.

[0039] 3. The seamless steel pipe handle 5 is made of DN50 galvanized pipe and welded to the upper side of the mounting base 4. The opening 8 forms an angle of 110°~130° with the axis of the handle 5. The seamless steel pipe handle 5 extends outward from the center of the longitudinal central axis at the rear of the mounting base 4, and the extension distance is sufficient to meet the needs of replacing the hanging roller 2. The seamless steel pipe handle 5 and the mounting base 4 are assembled and welded using multi-layer and multi-pass welding to prevent deformation and weld cracking under stress.

[0040] 4. The safety protection iron chain 6 is welded to the middle of the seamless steel pipe handle 5. It is made of G80 quenched steel chain, and its tensile strength reaches more than 800N / mm², which is much higher than that of ordinary iron chain and can withstand a large load. The hook is made of forged manganese steel hook. During use, the hook can rotate freely 360°. The hook mouth has a safety device to prevent it from falling off during pulling operations.

[0041] 5. The hand chain hoist is a national standard reinforced type 0.75 ton x 3 meter hoist with a specially designed ratchet-type precision brake, which can ensure safe and reliable operation. The sturdy and durable link chain is made of special alloy steel and has been heat-treated. It is suitable for heavy-duty operations. During use, it has the characteristics of good performance, easy maintenance, small size, light weight, easy to carry, low hand force, high efficiency, perfect structure and beautiful appearance.

[0042] After selecting and assembling the materials according to the above scheme, the inventors learned through practical application that the device can save manpower, is highly applicable, easy to operate, and improves the efficiency of disassembling idlers. Previously, it required 4-5 people to operate for 20 minutes, but now only 2 people need to operate for 3 minutes to remove the damaged idler and install the new idler.

[0043] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0044] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A conveyor belt idler replacement device, comprising a conveyor frame, idlers, and a replacement mechanism, characterized in that: The conveyor is equipped with a hanging idler roller. A replacement mechanism that can connect to the hanging chain on the hanging idler roller is installed on the side frame of the hanging idler roller. The replacement mechanism also includes a clamping base that can be positioned and supported on the frame, a handle that can extend the working stroke and act as a fulcrum, a safety protection chain, and a lever hoist as a power source. The end of the handle is installed on the upper side of the clamping base. The middle of the handle is connected to the lower end of the safety protection chain, and the upper end of the safety protection chain is connected to the frame through a hook. The top housing hook A of the lever hoist is engaged with the through hole at the front end of the handle. The lower end of the lever hoist is connected to the hanging chain on the hanging idler roller through the hook B at the end of the chain.

2. The conveyor belt idler roller replacement device according to claim 1, characterized in that: The mounting base has an opening on its lower side that is the same width as the cross-section of the frame.

3. The conveyor belt idler roller replacement device according to claim 1, characterized in that: The installation methods for the handle end and the upper side of the mounting base also include welding, threaded connection, and hinge limiting structure connection with adjustable rotation angle.

4. The conveyor belt idler roller replacement device according to claim 3, characterized in that: The handle end is connected to the upper side of the mounting base by welding, and the opening direction of the mounting base forms an angle of 110°~130° with the handle axis direction.

5. The conveyor belt idler roller replacement device according to claim 3, characterized in that: The handle end is connected to the upper side of the mounting base by a threaded structure. The threaded structure also includes a threaded sleeve welded to the side of the mounting base and a threaded rod located at the handle end. The opening direction of the mounting base forms an angle of 110° to 130° with the axial direction of the handle.

6. The conveyor belt idler roller replacement device according to claim 3, characterized in that: The handle end is connected to the upper side of the mounting base by an adjustable hinge limiting structure. The hinge limiting structure also includes a hinge support A, a slide groove, a hinge support B, a support plate, a shaft, and a locking nut. The hinge support A is located at the upper rear end of the mounting base and is rotatably connected to the handle end via a hinge structure. A slide groove is provided on the upper side of the mounting base in front of the hinge support A. The hinge support B is slidably installed in the slide groove via a shaft and can be positioned in the slide groove by tightening the locking nuts at both ends of the shaft. A support plate that is longer at the front and shorter at the back is rotatably installed on the hinge support B via a hinge structure.

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