Quick replacement device for lower idler of belt conveyor

Abstract

A quick replacement device for lower idler rollers of a belt conveyor, relating to the field of transportation device maintenance technology, includes a base frame, a lifting mechanism, and a supporting mechanism fixed to the top of the lifting mechanism. The base frame is rotatably connected to the bottom of the lifting mechanism. The supporting mechanism includes a crossbar fixed to the top of the lifting mechanism and at least two support grooves set on the crossbar. The support grooves open upward and are spaced apart along the length of the crossbar. A rotating cylinder with its axis of rotation perpendicular to the crossbar and a limiting mechanism to prevent the idler roller from deviating are set in the support groove. The crossbar can reciprocate vertically under the drive of the lifting mechanism. The lifting mechanism uses a scissor jack, which can be driven by a hand drill, to achieve rapid lifting and lowering of the scissor jack. This device has a reasonable structure and is easy to operate. Compared with traditional methods, the efficiency of replacing idler rollers is improved, while reducing the labor intensity and safety risks of operators.

Description

Technical Field

[0001] This utility model relates to the field of transportation device maintenance technology, specifically a quick replacement device for the lower idler roller of a belt conveyor. Background Technology

[0002] Belt conveyors are widely used for material transport in industries such as mining, metallurgy, food processing, papermaking, and printing. Replacing the lower idler roller is a common but tedious task during belt conveyor maintenance. It typically requires operators to manually pry the roller with a crowbar. However, because the ground beneath the roller is flat and lacks effective support, the operation is difficult. The lower idler roller generally weighs 15-30 kg, requiring four people to work together, which is time-consuming, labor-intensive, and poses a safety hazard of tool slippage and injury. During the replacement process, operators need to keep the roller suspended for extended periods, resulting in high labor intensity. Replacing a single idler roller usually takes more than 10 minutes, severely impacting production efficiency and operational safety.

[0003] Currently, the common solution in existing technology is to first use a lifting device to lift the return belt, separate the belt from the lower idler, and leave enough space for replacement. Then, the lower idler is replaced manually as described above. Although a lifting device is used when lifting the belt, which saves some manpower, the process of replacing the idler is still done manually. For some large belt conveyors, the idlers are often quite heavy, and the process of replacing the idlers is still very time-consuming and labor-intensive. Utility Model Content

[0004] This utility model provides a quick replacement device for the lower idler roller of a belt conveyor. The device has a simple structure, is easy to operate, and greatly improves the replacement efficiency. It achieves smooth lifting and precise positioning of the idler roller through a mechanical device, avoiding the uncertainty of manual prying.

[0005] To achieve the above objectives, the specific solution adopted by this utility model is as follows: a quick replacement device for the lower idler roller of a belt conveyor, including a base frame, a lifting mechanism, and a bearing mechanism fixed on the top of the lifting mechanism. The base frame is rotatably connected to the bottom of the lifting mechanism. The bearing mechanism includes a crossbar fixed on the top of the lifting mechanism and at least two support grooves arranged on the crossbar. The support grooves open upward and are spaced apart along the length of the crossbar. A rotating cylinder with its rotation axis perpendicular to the crossbar and a limiting mechanism to prevent the idler roller from deviating are arranged in the support groove. The crossbar can reciprocate in the vertical direction under the drive of the lifting mechanism.

[0006] As an optimized solution for the aforementioned quick replacement device for the lower idler roller of a belt conveyor: the base frame is rotatably connected to the bottom of the lifting mechanism via a tapered bearing.

[0007] As another optimized solution for the aforementioned quick replacement device for the lower idler roller of a belt conveyor, the lifting mechanism is a scissor jack.

[0008] As another optimized solution for the aforementioned quick replacement device for the lower idler roller of a belt conveyor: one end of the screw of the scissor jack is provided with an external hexagonal head.

[0009] As another optimized solution for the aforementioned quick replacement device for the lower idler roller of a belt conveyor: the rotating drum is rotatably mounted in the support groove via a fixed shaft, and the limiting mechanism is a baffle or stop bar vertically mounted on the fixed shaft, with the baffle or stop bar located on both sides of the rotating drum.

[0010] As another optimized solution for the aforementioned quick replacement device for the lower idler roller of a belt conveyor: a limiting groove is provided on the crossbar, the limiting groove is a U-shaped structure with the opening facing upward, and its width is less than the length of the rotating drum.

[0011] As another optimized solution for the aforementioned quick replacement device for the lower idler roller of a belt conveyor: the limiting groove is detachably connected to the crossbar by bolts.

[0012] As another optimized solution for the aforementioned quick replacement device for the lower idler roller of a belt conveyor: the crossbar is provided with a limiting block that can be engaged with the gap between it and the rotating drum to limit the rotation of the rotating drum.

[0013] As another optimized solution for the aforementioned quick replacement device for the lower idler roller of a belt conveyor: the side of the limiting block closest to the rotating drum is an inclined surface.

[0014] As another optimized solution for the aforementioned quick replacement device for the lower idler roller of a belt conveyor, the limiting block is made of rubber.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. By setting a tapered bearing between the base frame and the lifting mechanism, the upper structure of the entire device can rotate freely in the horizontal direction, which makes it easy to adjust the position after lifting the roller, so that the two ends of the roller are offset from the groove of the lifting lug, and the roller can be pulled out without moving the entire device.

[0016] 2. The rotating drum is designed to rotate, creating rolling contact when the rollers are pulled out, making the pulling process smoother and preventing jamming.

[0017] 3. Limiting mechanisms are installed on both sides of the rotating drum to restrict the lateral movement of the idler rollers during lifting and rotation, prevent the idler rollers from rolling off, and ensure the safety of operators. Attached Figure Description

[0018] Figure 1 This is a front view structural diagram of the present invention in Embodiment 1; Figure 2 This is a side view of the structure of the present invention in Embodiment 1; Figure 3 This is a schematic diagram of the lifting mechanism of this utility model during compression in Embodiment 1; Figure 4 This is a schematic diagram of the lifting mechanism of this utility model during lifting in Embodiment 1; Figure 5 This is a front view structural diagram of the present invention in Embodiment 2; Figure 6 This is a schematic diagram of the connection structure of the limiting groove of this utility model in Embodiment 2; Reference numerals: 1. Base frame; 2. Tapered bearing; 3. Lifting mechanism; 301. Lead screw; 3011. External hexagonal head; 302. Saddle; 4. Bearing mechanism; 401. Crossbar; 402. Rotary drum; 403. Support groove; 404. Fixed shaft; 5. Limiting assembly; 6. Limiting block; 7. Limiting groove; 8. Idler roller; 9. Belt; 10. Mounting beam; 11. Lifting lug; 12. Lifting lug groove. Detailed Implementation

[0019] The technical solution of this utility model will be further described in detail below with reference to specific embodiments. Parts not described or disclosed in detail in the following embodiments of this utility model should be understood as prior art known or should be known by those skilled in the art.

[0020] Example 1 like Figures 1 to 4 As shown, this utility model provides a quick replacement device for the lower idler roller of a belt conveyor, including a base frame 1, a lifting mechanism 3, and a bearing mechanism 4 fixed on the top of the lifting mechanism 3. The base frame 1 is rotatably connected to the bottom of the lifting mechanism 3. The base frame 1 is welded from 50*50 mm square steel pipes and has an overall rectangular frame structure. Its length and width are both two-thirds of the length of the idler roller 8. Taking an idler roller 8 with a length of 1400 mm as an example, the dimensions of the base frame 1 are 930*930 mm to ensure sufficient stability and load-bearing capacity.

[0021] The base frame 1 is rotatably connected to the bottom of the lifting mechanism 3 via a tapered bearing 2. The outer ring of the tapered bearing 2 is welded and fixed to the center of the base frame 1, and the inner ring is welded and fixed to the bottom of the lifting mechanism 3. The diameter of the tapered bearing 2 is greater than 15 cm, and the radial load capacity is greater than 500 N, which can meet the force requirements for replacing various specifications of idler rollers 8. The lifting mechanism 3 can rotate 360 ​​degrees horizontally relative to the base frame 1, thereby adjusting the position of the idler roller 8 after lifting it, so that the two ends of the idler roller 8 are misaligned with the lifting lugs 12 on the mounting beam 10.

[0022] The lifting mechanism 3 is a scissor jack with a rated load capacity of 1.5 tons. One end of the scissor jack's screw 301 has an external hexagonal head 3011 for connection to a drive tool. Specifically, an electric drill serves as the power source, with a sleeve connected to its output end. The other end of the sleeve has an internal hexagonal hole that matches the external hexagonal head 3011. The electric drill drives the sleeve to rotate, thereby rotating the screw 301 and lifting or lowering the scissor jack, significantly improving operational efficiency and reducing manpower consumption.

[0023] In addition to being driven by a hand drill, the lead screw of the scissor jack 301 can also be driven by a cross socket wrench for use in environments without power.

[0024] The supporting mechanism 4 includes a crossbar 401 and at least two support slots 403 disposed on the crossbar 401. The crossbar 401 is horizontally welded to the saddle 302 at the top of the scissor jack and is made of 30*30 mm square steel pipe. The crossbar 401 can reciprocate vertically under the drive of the scissor jack. The length of the crossbar 401 is shorter than the length of the idler roller 8. Preferably, the design length of the crossbar 401 is 2 / 3 of the length of the idler roller. Taking a 1400 mm idler roller 8 as an example, the length of the crossbar 401 is 930 mm, so that the crossbar 401 will not collide with the lifting lugs 11 on both sides of the mounting beam 10 during the upward process. The support slots 403 open upward and are spaced apart along the length of the crossbar 401. When there are two support slots 403, they are symmetrically arranged on both sides of the crossbar 401. For large idler rollers 8, the number of support slots 403 can be three or more, which are equally spaced along the length of the crossbar 401. A rotating cylinder 402, with its axis of rotation perpendicular to the crossbar 401, is installed within the support groove 403. The rotating cylinder 402 is rotatably mounted within the support groove 403 via a fixed shaft 404. The rotating cylinder 402 is made of bearing steel with a diameter of 30 mm, with a hardened surface and lubricated. A gap is maintained between the rotating cylinder 402 and the crossbar 401 to ensure smooth rotation of the rotating cylinder 402. A limit block 6, a square shape made of rubber, is installed below the rotating cylinder 402. When the limit block 6 engages in the gap between the rotating cylinder 402 and the crossbar 401, one side contacts the bottom of the rotating cylinder 402, and the opposite side contacts the upper surface of the crossbar 401, thus limiting the rotation of the rotating cylinder 402 through friction. The side of the limit block 6 closest to the rotating cylinder 402 is inclined at an angle of 20 to 30 degrees, allowing for better engagement and disengagement. The limiting block 6 can prevent the idler roller 8 from sliding accidentally when it is not pulled out, thus improving the safety of the device during use.

[0025] The limiting block 6 is connected to the crossbar 401 by a rope or chain to prevent it from being lost.

[0026] Limiting mechanisms 5 are provided on both sides of the rotating drum 402 to prevent the idler roller 8 from deviating. The limiting mechanism 5 is a baffle or stop bar that is vertically welded and fixed on the fixed shaft 404 and symmetrically arranged. The baffle or stop bar is located on both sides of the rotating drum 402. In this embodiment, baffles are used. The distance between the baffles on both sides of the rotating drum 402 is 1 to 2 cm greater than the diameter of the idler roller 8, which ensures that the idler roller 8 can be pulled out smoothly without being too tight. When the top of the rotating drum 402 contacts the idler roller 8, the highest point of the baffle is 1 cm higher than the radius height of the idler roller 8. This design can effectively prevent the idler roller 8 from rolling off during lifting or rotation, ensuring operational safety.

[0027] In use, firstly, use the belt lifting device to lift the belt 9 above the idler roller 8 to be replaced. This is existing technology and will not be described in detail. Place this device directly below the idler roller 8 to be replaced. Initially, the scissor jack is in a compressed state. Adjust the direction of the crossbar 401 so that it is parallel to the length direction of the idler roller 8. Start the electric drill, and drive the lead screw 301 to rotate through the sleeve, causing the scissor jack to lift. The crossbar 401 rises accordingly, and the rotating drum 402 lifts the idler roller 8, raising it until its two ends of the shaft are disengaged from the lifting lug groove 12. At this time, because the rotating drum 402 is equipped with baffles at both ends, the idler roller 8 will not shift.

[0028] Subsequently, the operator rotates the entire upper structure of the device, namely the lifting mechanism 3 and the bearing mechanism 4, using the tapered bearings to offset the two ends of the idler roller 8 from the lifting lugs 11. The limiting block 6 is manually removed, and the old idler roller 8 is pulled out. Since the rotating drum 402 can rotate at this time, rolling friction is generated when pulling out the idler roller 8, allowing the operator to easily remove it. When installing the new idler roller 8, one side of the new idler roller 8 is placed on the rotating drum 402 and pushed inward until the new idler roller 8 returns to the center position of the device. Then, the limiting block 6 is manually inserted under the rotating drum 402, which restricts rotation and prevents the new idler roller 8 from slipping off. Then, the entire upper structure of the device is rotated in the opposite direction to align the shaft ends of the new idler roller 8 with the lifting lug grooves 12. Finally, the electric drill drives the lead screw 301 in the reverse direction, causing the scissor jack to descend, and the new idler roller 8 is then inserted into the lifting lug grooves 12, completing the replacement process.

[0029] This device requires only two people to operate, with one person as the main operator and the other as the assistant inspector. The replacement time has been reduced from 10 minutes to less than 150 seconds. Compared with traditional methods, efficiency has been greatly improved, the labor intensity of operators has been significantly reduced, and safety has been significantly enhanced.

[0030] The above are the basic embodiments of this utility model. Further improvements, optimizations, and limitations can be made based on the above to obtain the following embodiments: Example 2 This embodiment is an improvement on embodiment 1. Its main structure is the same as that of embodiment 1, but the improvement lies in: [The following is a more detailed description of the improvement.] Figure 5 , Figure 6 As shown, when replacing idler rollers 8 with different diameters, especially small-diameter idler rollers 8, the idler roller 8 may shift within the limiting mechanism 5. To solve this problem, a limiting groove 7 is provided on the crossbar 401. In this embodiment, there are two limiting grooves 7, which are respectively set inside the support groove 403. For some longer idler rollers, the number of limiting grooves 7 can be appropriately increased. The limiting groove 7 has an upward-opening U-shaped structure. Its groove width is less than the length of the rotating drum 402, and its height is the same as the height of the baffle in embodiment 1. A through hole is opened at the bottom of the limiting groove 7, and a through hole is opened on the crossbar 401. Bolts pass through the through hole at the bottom of the limiting groove 7 and the through hole on the crossbar 401 in sequence. A fastening nut is provided at the end of the bolt, thereby realizing a detachable connection between the limiting groove 7 and the crossbar 401.

[0031] When replacing a smaller diameter idler roller 8, there is a large amount of play between the idler roller 8 and the baffles on both sides of the rotating drum 401. This can easily lead to misalignment during lifting or rotation. The operator can select a suitable limiting groove 7 based on the diameter of the idler roller 8 to be replaced and install it on the crossbar 401 using the connection method described above. At this point, the smaller diameter idler roller 8 will contact the inner wall of the limiting groove 7. During continued pulling or adjustment, the limiting groove 7 will provide guidance and alignment, forcing the idler roller 8 back to the centerline position, thus ensuring stability during the replacement process. It can be removed when not needed. By setting limiting grooves 7 with different widths, this device can flexibly adapt to the replacement needs of various specifications of idler rollers 8, further improving the versatility and flexibility of the device.

[0032] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A quick-change device for the lower idler roller of a belt conveyor, characterized in that: The system includes a base frame (1), a lifting mechanism (3), and a bearing mechanism (4) fixed on top of the lifting mechanism (3). The base frame (1) is rotatably connected to the bottom of the lifting mechanism (3). The bearing mechanism (4) includes a crossbar (401) fixed on top of the lifting mechanism (3) and at least two support grooves (403) on the crossbar (401). The support grooves (403) are open upward and spaced apart along the length of the crossbar (401). A rotating drum (402) with a rotation axis perpendicular to the crossbar (401) and a limiting mechanism (5) to prevent the roller (8) from deviating are provided in the support groove (403). The crossbar (401) can reciprocate in the vertical direction under the drive of the lifting mechanism (3).

2. The quick-change device for the lower idler roller of a belt conveyor according to claim 1, characterized in that: The base frame (1) is rotatably connected to the bottom of the lifting mechanism (3) via a tapered bearing (2).

3. The quick-change device for the lower idler roller of a belt conveyor according to claim 1, characterized in that: The lifting mechanism (3) is a scissor jack.

4. The quick-change device for the lower idler roller of a belt conveyor according to claim 3, characterized in that: The scissor jack has an external hexagonal head (3011) at one end of its screw rod (301).

5. The quick-change device for the lower idler roller of a belt conveyor according to claim 1, characterized in that: The rotating drum (402) is rotatably mounted in the support groove (403) via a fixed shaft (404). The limiting mechanism (5) is a baffle or stop bar vertically mounted on the fixed shaft (404), and the baffle or stop bar is located on both sides of the rotating drum (402).

6. The quick-change device for the lower idler roller of a belt conveyor according to claim 1, characterized in that: The crossbar (401) is provided with a limiting groove (7), which is a U-shaped structure with an upward opening and its width is less than the length of the rotating cylinder (402).

7. A quick-change device for the lower idler roller of a belt conveyor according to claim 6, characterized in that: The limiting groove (7) is detachably connected to the crossbar (401) by bolts.

8. A quick-change device for the lower idler roller of a belt conveyor according to claim 1, characterized in that: The crossbar (401) is provided with a limiting block (6) that can be engaged in the gap between it and the rotating drum (402) to limit the rotation of the rotating drum (402).

9. A quick-change device for the lower idler roller of a belt conveyor according to claim 8, characterized in that: The limiting block (6) has an inclined surface on the side near the rotating cylinder (402).

10. A quick-change device for the lower idler roller of a belt conveyor according to claim 9, characterized in that: The limiting block (6) is made of rubber.

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