Modular adjustable belt pulley servicing device

Abstract

The application relates to a modular adjustable belt pulley maintenance device, characterized in that the device comprises a supporting part, a rotating part, a moving feeding part, a turning and milling polishing part and an electric control part, the supporting part is composed of a left supporting frame and a right supporting frame, the rotating part is composed of a speed reducer assembly, a driving wheel and a bearing wheel, and is symmetrically arranged on the top of the left and right supporting frames respectively; the moving feeding part comprises an X-axis sliding table base, an X-axis sliding rail and a stepping motor A; the turning and milling polishing part comprises a Y-axis sliding table, a stepping motor B installed on the Y-axis sliding table, an elastic cylinder type working head clamp connected with the output end of the stepping motor B and a working head installed on the elastic cylinder type working head clamp; and the electric control part comprises a control box and a control panel; by using the belt pulley maintenance device, the working head can be replaced, and all maintenance processes such as belt pulley surface cleaning, roughening, glue hanging, rolling, surface diamond-shaped groove and edge trimming treatment can be conveniently completed.

Description

Technical Field

[0001] This utility model belongs to the field of belt pulley repair technology, and in particular relates to a modular adjustable belt pulley repair device. Background Technology

[0002] As the core transmission component of belt conveyors, the rubber surface of the belt pulley will gradually wear down after a period of use due to long-term friction with the belt and the hard abrasion caused by slag inclusions. When the rubber surface wears to its limit, in order to ensure the normal operation and transmission efficiency of the belt conveyor, the belt pulley needs to be taken off the production line for repair. It is sent to a belt pulley repair shop and lifted by a crane onto a large lathe. One side of the pulley shaft is fixed by the lathe's chuck, and the other side of the pulley shaft is fixed by the center pin at the other end of the lathe. The rotation of the lathe's chuck drives the pulley to rotate. The lathe's left and right moving cutting tool is used to remove the rubber covering the surface of the pulley's steel barrel. After the rubber covering the pulley is cleaned, a cleaning agent is applied to the surface of the pulley steel barrel to ensure that there is no dust or impurities. Then, it is lifted by a crane to be placed in an oven and installed upright. Polyurethane is poured using a casting machine and hot vulcanized. Then, it is lifted to a large lathe for trimming and diamond groove treatment. This traditional hot-casting rubber repair method has many repair procedures, involves multiple processing equipment and processes, resulting in a long repair period. It also requires the purchase of a large number of spare parts to meet the needs of on-site replacement. To reduce spare parts and lower inventory, proactive maintenance is conducted on non-drive belt pulleys such as tail pulleys, top pulleys, counterweight pulleys, and idler pulleys of belt conveyors. When the rubber surface thickness of existing pulleys on the production line wears down to approximately 10mm, they are replaced and taken off the line. After the removed pulleys are smoothed, a cold glue bonding process is used to attach a piece of belt with two layers remaining and a thickness of 10mm, quickly making them available as spare parts. For brand-new pulleys on the production line, the surface is roughened, and a piece of belt with two layers remaining and a thickness of 10mm is bonded using cold glue to extend their service life. However, this process does not address the surface wear of the pulleys. All maintenance procedures, including leveling, roughening, applying adhesive, compacting, and treating the surface with diamond grooves, require maintenance personnel to manually level the belt pulley surface with a scraper, roughen the belt pulley surface with a roughening machine, hammer and compact the bonded adhesive surface with a rubber mallet, and groove and shape the belt pulley surface and sides with a belt cutter. The belt pulley also needs to be flipped during maintenance. All of these processes are done manually, resulting in high labor intensity, a large number of maintenance personnel, and inconsistent maintenance quality depending on the technical skills of the maintenance personnel. Therefore, there is an urgent need for an electric maintenance device that can replace manual labor and reduce the labor intensity and number of maintenance personnel required. Summary of the Invention

[0003] The purpose of this invention is to provide a modular and adjustable belt pulley maintenance device that can complete all maintenance procedures such as belt pulley surface cleaning, roughening, glue application, rolling, surface diamond groove treatment, and edge trimming.

[0004] The objective of this utility model is achieved through the following technical solution: This utility model discloses a modular adjustable belt pulley maintenance device, characterized in that it includes a support part, a rotating part, a moving feed part, a turning, milling and grinding part, and an electrical control part. The supporting structure consists of a left support frame and a right support frame symmetrically arranged thereto. The right support frame of the left support frame has a basically the same structure as the left support frame, including a lower base plate, an upper plate, four columns, and a slide support plate. The upper plate and lower base plate are fixed together by the four columns to form a support frame. The slide support plate is mounted on a column on one side of the support frame via a tripod, making the overall support frame stepped. The upper plate has a reducer mounting hole, a drive wheel mounting hole, and a long, narrow load-bearing wheel mounting hole for mounting the load-bearing wheel. The slide support plate has a long, narrow X-axis slide base mounting hole. The slide support plate of the left support frame also has a control panel mounting hole. The rotating part consists of a reducer assembly, a drive wheel, and a load-bearing wheel, which are symmetrically placed on the top of the left and right support frames, respectively. The moving feed part includes an X-axis slide base, an X-axis slide rail fixed on the upper part of the X-axis slide base, a stepper motor A at the end of the X-axis slide rail 42, and the two ends of the X-axis slide base are respectively fixed to the elongated X-axis slide base foot holes on the two slide support plates of the left support frame and the right support frame by sliding bolt assembly. The milling and grinding section includes a Y-axis slide table mounted on the X-axis slide rail and slidably connected to the X-axis slide rail, a stepper motor B mounted on the Y-axis slide table and an elastic cylindrical working head clamp connected to the output end of the stepper motor B, and a working head mounted on the elastic cylindrical working head clamp. The electrical control unit includes a control box and a control panel. The control box is housed within the left support frame and is electrically connected to the motor, stepper motor A, and stepper motor B of the reducer assembly. The control box is also connected to a three-phase five-wire AC power supply. The control panel is secured at an angle using bolts. On the bottom holes of the control panel.

[0005] Preferably, the X-axis slide base is made of H-beams with a length of 2.3m and a width of 200*200mm. 10mm thick steel plate ribs are symmetrically welded to the middle and both sides of the X-axis slide base. Two rows of upper foot holes are opened on the top for fixing the X-axis slide rail. Lower foot holes are opened on the lower left side of the X-axis slide base for fixing the slide base pad to the long strip-shaped X-axis slide base foot holes on the left support frame. A horizontal long strip hole is opened on the lower right side of the X-axis slide base for fixing the slide base pad and bolt assembly to the right support frame, thus connecting the left support frame, the right support frame, and the X-axis slide base into a whole structure.

[0006] Preferably, the working head is a milling cutter head, a cup-shaped wire wheel, a glue roller, a cutting cutter head, and a trimming cutter head.

[0007] Advantages of this utility model: This utility model discloses a modular and adjustable belt pulley maintenance device. By utilizing reducers on both sides of the moving part to drive the drive wheel, and using the friction between the drive wheel and the axle surfaces on both sides of the belt pulley to drive the belt pulley's rotation, the device can replace manual labor in a one-stop process to complete all maintenance procedures on the belt pulley, including surface cleaning, roughening, adhesive application, rolling, surface diamond groove finishing, and edge trimming. This significantly improves the efficiency and quality of belt pulley maintenance, reduces enterprise maintenance costs and spare parts inventory, and effectively meets the practical needs of industrial production for rapid self-inspection and repair of belt pulleys. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of the modular adjustable belt pulley maintenance device of this utility model; Figure 2 This is a schematic diagram of the left-side support frame; Figure 3 A schematic diagram of the X-axis slide base and slide pad; Figure 4 A schematic diagram of the working state of the modular adjustable belt pulley maintenance device; Figure 5 for Figure 4 Side view.

[0009] In the diagram: left support frame 11, right support frame 12, lower base plate 111, upper plate 112, four columns 113, slide support plate 114, tripod 115, reducer foot hole 1121, drive wheel foot hole 1122, long strip load-bearing wheel foot hole 1123, control panel foot hole 1141, long strip X-axis slide base foot hole 1142, reducer assembly 21, drive wheel 22, load-bearing wheel 23, control box 31, control panel 32, X-axis slide base 41, X-axis slide rail 42, stepper motor A421, rib plate 43, lower foot hole 44, horizontal long strip hole 45, upper foot hole 46, slide base pad 47, Y-axis slide 51, stepper motor B52, working head 53, and 6 is a belt pulley. Detailed Implementation

[0010] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0011] like Figure 1-5 As shown, this utility model discloses a modular adjustable belt pulley maintenance device, characterized in that it includes a support part, a rotating part, a moving feed part, a turning, milling and grinding part, and an electrical control part. The supporting structure consists of a left support frame 11 and a right support frame 12 symmetrically arranged with the left support frame 11. The right support frame 12 of the left support frame 11 has a basically the same structure, including a lower base plate 111, an upper plate 112, four columns 113, and a slide support plate 114. The upper plate 112 and the lower base plate 111 are fixed together by the four columns 113 to form a supporting frame. The slide support plate 114 is set on the column 114 on one side of the supporting frame by a tripod 115, so that the supporting frame as a whole is in the shape of a triangle. The upper plate 112 is stepped; it has a reducer mounting hole 1121 for mounting the reducer assembly, a drive wheel mounting hole 1122 for mounting the drive wheel, and a long, narrow load-bearing wheel mounting hole 1123 for mounting the load-bearing wheel; it has a strip-shaped X-axis slide base mounting hole 1142 on the slide support plate 114 for fixing the control panel base and mounting the X-axis slide base; it also has a control panel mounting hole 1141 on the slide support plate 114 of the left support frame 11. The rotating part consists of a reducer assembly 21, a drive wheel 22 and a load-bearing wheel 23, which are symmetrically placed on the top of the left support frame 11 and the right support frame 12, respectively. The moving feed part includes an X-axis slide base 41, an X-axis slide rail 42 fixed on the upper part of the X-axis slide base, a stepper motor A421 at the end of the X-axis slide rail 42, and the two ends of the X-axis slide base are respectively fixed to the elongated X-axis slide base foot holes 1142 on the two slide support plates 114 of the left support frame 11 and the right support frame 11 by sliding bolt assembly; The milling and grinding section includes a Y-axis slide table 51 mounted on and slidably connected to the X-axis slide rail 42, a stepper motor B52 mounted on the Y-axis slide table 51, and an elastic cylindrical working head chuck connected to the output end of the stepper motor B52, and a working head 53 mounted on the elastic cylindrical working head chuck; the working head 53 is a milling cutter disc, a cup-shaped wire wheel, a glue roller, and a cutting tool.

[0012] The electrical control section includes a control box 31 and a control panel 32. The control box 31 is installed inside the left support frame 11. The control box 31 is electrically connected to the motor 21, stepper motor A421 and stepper motor B52 of the reducer assembly, and the control box 31 is connected to a three-phase five-wire AC power supply. The control panel 32 is fixed at an angle to the bottom foot hole 1141 of the control panel by bolts.

[0013] The X-axis slide base 41 of this utility model is made of H-beam steel with a length of 2.3m and a width of 200*200mm. 10mm thick steel plate ribs 43 are symmetrically welded to the middle and both sides of the X-axis slide base 41. Two rows of upper foot holes 46 are opened on the top of the ribs for fixing the X-axis slide rail 42. Lower foot holes 44 are opened on the lower left side of the X-axis slide base 41 for fixing to the elongated X-axis slide base foot holes 4112 on the left support frame through the slide base pad 47. A transverse elongated hole 45 is opened on the lower right side of the X-axis slide base 41 for fixing to the right support frame 12 through the slide base pad 47 and bolt assembly. The transverse elongated hole 45 can adjust the connection position according to the length of the belt pulley. The left support frame 11, the right support frame 12 and the X-axis slide base 42 are connected into an integral structure.

[0014] The control box 31 of this utility model contains a motor frequency converter system for controlling the reducer assembly, a frequency converter for controlling the stepper motor 52, and corresponding power and control circuits. The control system inside the control box can control the forward and reverse inching, continuous operation, and speed regulation of the reducer assembly motor, and control the speed and direction of the stepper motor on the Y-axis slide. The control system of the control box is existing technology and will not be described in detail here.

[0015] The control panel 32 of this utility model is equipped with start / stop and speed adjustment for the stepper motor, as well as an emergency stop button, a start button for the motor inverter system, and a power indicator light. The control panel 32 facilitates the operation and monitoring of the equipment.

[0016] The working principle of this utility model is as follows: 1. The first step is to assemble the modular adjustable belt pulley 6 maintenance device. After the belt pulley 6 is taken off the production line, the distance between the bearing seats on both sides of the belt pulley 6 is measured to determine the distance between the left support frame 11 and the right left support frame 12 of the device. The bearing seats on both sides of the belt pulley are disassembled, and the diameter of the belt pulley axle is measured to determine the distance between the drive wheel 22 and the load-bearing wheel 23. Based on the measured data, the distance between the load-bearing wheel 23 and the drive wheel 22 is first adjusted and fixed. Then, the distance between the left support frame 11 and the right left support frame 12 is adjusted. Finally, the axle of the belt pulley to be maintained is hoisted and placed between the load-bearing wheel 23 and the drive wheel 22.

[0017] 2. Place the X-axis slide base 41 on the X-axis slide support plate 114 of the left support frame 11 and the right left support frame 12, and install the X-axis slide rail 42 on the X-axis slide base 41; place the Y-axis slide 51 on the upper part of the X-axis slide rail 42 and slide it in connection with the X-axis slide rail 42, install the stepper motor 52 on the Y-axis slide 51, and connect the output of the stepper motor 52 to the elastic cylindrical working head clamp through the coupling, and install the working head 53 on the elastic cylindrical working head clamp; First, install the milling cutter disc. By adjusting the thickness of the slide base pads 47 on both sides, ensure that the horizontal center line of the belt pulley 6 is aligned with the center line of the milling cutter disc of the stepper motor 52.

[0018] 3. Adjust the relative position of the X-axis slide base 41 and the belt pulley according to the diameter of the belt pulley 7. After ensuring parallelism, fix it with the base bolts. Quickly connect the control box 31 to the reducer assembly 21 motor, stepper motor 421A and stepper motor B52 through the power cord plug. Connect the control box 31 to a three-phase five-wire AC power supply to complete the final assembly preparation work of the belt pulley maintenance device.

[0019] 4. Activate the control button for stepper motor A on control panel 32 to move the milling cutter head to the left side of the belt pulley. Adjust the feed rate of stepper motor B on the Y-axis slide 51 according to the required cutting thickness on the belt pulley surface. Activate the control button for stepper motor B, adjust its speed, and control the stepper motor A on the X-axis slide to rotate forward. Control stepper motor B to move from the left side of the belt pulley to the right. As stepper motor B moves to the right, its high-speed rotating milling cutter head rapidly cuts the belt. When the belt pulley is moved to the far right and stops, the jog control reducer assembly motor rotates forward to drive the pulley to rotate an angle. Then, the stepper motor A of the X-axis slide rail is controlled to rotate in reverse, causing the stepper motor B to move to the left. This cycle of left and right movement is repeated to cut the surface of the belt pulley. Finally, the reducer assembly motor is controlled to rotate continuously forward to drive the belt pulley to rotate at a constant speed, while the stepper motor A of the X-axis slide rail rotates slowly. This causes the milling cutter disc at the head of the stepper motor B to roll the surface of the belt pulley, completing the final cutting work on the belt pulley.

[0020] 5. Remove the milling cutter head at the front end of stepper motor B and replace it with a cup-shaped steel wire wheel. After adjusting the feed amount of stepper motor A on the Y-axis slide rail, lock it. Start stepper motor B, adjust the motor speed of stepper motor B, and roughen the surface of the belt pulley in the same way.

[0021] 6. Disassemble the cup-shaped steel wire wheel at the front end of stepper motor B and replace it with a pressure wheel. Then, proceed with the adhesive bonding. First, roughen the bonding surfaces of the rubber sheets, apply a coat of cold adhesive, and wait for the surface to dry before applying another coat. At the same time, apply a coat of cold adhesive to the surface of the belt pulley. When the adhesive on the rubber sheets and belt pulley surfaces is no longer sticky to the touch, attach one end of the rubber sheet to the horizontal line of the belt pulley, while simultaneously controlling the reducer assembly motor to jog forward to drive the belt pulley to rotate, thus rotating the rubber sheet. Cover the surface of the belt pulley bit by bit, while controlling the left and right movement of the Y-axis slide table 51 on the X-axis slide rail. Use the pressure roller at the front end of the stepper motor B to compact the bonding surface. After cutting off the excess rubber at the bonding joint with a knife to complete the closure of the adhesive surface, remove the pressure roller at the front end of the stepper motor B and replace it with a 120-degree V-shaped trimming cutter head. Adjust the rotation speed of the belt pulley and move the stepper motor B to both sides of the belt pulley. By controlling the feed of the stepper motor B, cut off the excess adhesive surface on both sides of the belt pulley.

[0022] 7. Finally, the diamond-shaped groove on the surface of the belt pulley 6 is cut. First, remove the 120-degree V-shaped trimming head at the front end of the stepper motor B and replace it with a 90-degree V-shaped trimming head. Adjust the feed rate of the stepper motor B according to the depth of the diamond-shaped groove. Start the stepper motor B and adjust the speed of the stepper motor B, as well as the rotation speed of the belt pulley and the moving speed of the stepper motor A, to cut the diamond-shaped groove on the surface of the belt pulley and complete the final inspection of the belt pulley.

Claims

1. A modular adjustable belt pulley maintenance device, characterized in that, It includes a support section, a rotating section, a moving feed section, a turning, milling, and grinding section, and an electrical control section. The support section consists of a left support frame and a right support frame arranged symmetrically to the left support frame. The left and right support frames have the same structure, including a lower base plate, an upper plate, four columns, and a slide support plate. The upper plate and the lower base plate are fixed together by the four columns to form a support frame. The slide support plate is mounted on a column on one side of the support frame via a tripod, making the support frame as a whole stepped. The upper plate has a reducer foot hole, a drive wheel foot hole, and a long strip-shaped load-bearing wheel foot hole for mounting the load-bearing wheel. The slide support plate has a long strip-shaped X-axis slide base foot hole. The slide support plate of the left support frame also has a control panel foot hole. The rotating part consists of a reducer assembly, a drive wheel, and a load-bearing wheel, which are symmetrically placed on the top of the left and right support frames, respectively. The moving feed part includes an X-axis slide base, an X-axis slide rail fixed on the upper part of the X-axis slide base, a stepper motor A at the end of the X-axis slide rail, and the two ends of the X-axis slide base are respectively fixed to the elongated X-axis slide base foot holes on the two slide support plates of the left support frame and the right support frame by sliding bolt assembly. The milling and grinding section includes a Y-axis slide table mounted on the X-axis slide rail and slidably connected to the X-axis slide rail, a stepper motor B mounted on the Y-axis slide table and an elastic cylindrical working head chuck connected to the output end of the stepper motor B, and a working head mounted on the elastic cylindrical working head chuck. The electrical control unit includes a control box and a control panel. The control box is housed within the left support frame and is electrically connected to the motor, stepper motor A, and stepper motor B of the reducer assembly. The control box is also connected to a three-phase five-wire AC power supply. The control panel is secured at an angle using bolts. On the bottom holes of the control panel.

2. The modular adjustable belt pulley maintenance device according to claim 1, characterized in that, The X-axis slide base is made of 2.3m long, 200*200mm wide H-beams. Symmetrical 10mm thick steel ribs are welded to the middle and sides of the X-axis slide base. Two rows of upper foot holes are provided on the top for fixing the X-axis slide rail. Lower foot holes are provided on the lower left side of the X-axis slide base for fixing the slide base pad to the elongated X-axis slide base foot holes on the left support frame. A transverse elongated hole is provided on the lower right side of the X-axis slide base for fixing the slide base pad and bolt assembly to the right support frame, thus connecting the left support frame, right support frame, and X-axis slide base. Connect them into a whole structure.

3. The modular adjustable belt pulley maintenance device according to claim 1, characterized in that, The working head includes a milling cutter head, a cup-shaped wire wheel, an adhesive roller, a cutting cutter head, and a trimming cutter head.

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