Belt conveyor fixed upper idler

Abstract

The utility model relates to the technical field of belt conveyor, disclose a kind of belt conveyor fixed upper carrier roller, including several along the transport direction arrangement carrier roller group, each carrier roller group includes crossbeam and several carrier rollers along crossbeam arrangement, the number of carrier roller in each carrier roller group is greater than 3, the groove angle of the side carrier roller in it is greater than 45 °, and the conveying belt is laid on the surface of all carrier rollers.The utility model is provided with multiple carrier rollers, which load the conveying belt and increase the groove angle of the side carrier roller, have the beneficial effects of improving the load-carrying capacity and high-speed stability of the conveying belt in the horizontal arc segment, ensuring the conveying capacity, significantly reducing the bending stress of the conveying belt, and smoothly transitioning the conveying belt in the carrier roller group.

Description

Technical Field

[0001] This utility model relates to the field of belt conveyor technology, and in particular to a fixed upper idler roller for a belt conveyor. Background Technology

[0002] Belt conveyors are a type of bulk material transport equipment that has been developed for many years and is widely used in industries such as mining, ports, and metallurgy. With continuous technological advancements and changing societal needs, belt conveyors are increasingly used for longer distances. Compared to the traditional method of bridging multiple short-distance belt conveyors, single long-distance curved belt conveyors are more cost-effective and simpler to manufacture and maintain, thus leading to their increasingly widespread and mature application across various industries.

[0003] These long-distance belt conveyors are typically all-terrain conveyors, needing to traverse complex and varied terrains, including mountains, valleys, and highways. Therefore, they are often installed using an overhead integrated truss structure. In such lines, the design of long horizontal turning sections (horizontal arcs) is crucial. To balance the centrifugal force generated by the conveyor belt and materials during turns, and to prevent belt deviation or material spillage, the traditional approach is to install trough-shaped idler groups in a "lower inside, higher outside" configuration on the horizontal arcs, utilizing the component of gravity to provide centripetal force.

[0004] At this point, due to the height difference on both sides, the trough shape of the trough idler group becomes shallower. Traditional trough idler groups (such as three-roller groups) are limited by structural and material mechanical properties, and their trough angle cannot exceed 45°. This results in a reduction in the effective theoretical depth (sag) of the trough idler group, significantly reducing the actual cross-sectional area of ​​the material to be carried, greatly reducing the load capacity of the conveyor belt, restricting the load-bearing capacity of the conveyor belt, and also being detrimental to the stability of the conveyor belt during transportation. In addition, traditional trough idler groups have fewer support points, and the conveyor belt is subjected to concentrated force. Under high-speed operation conditions, it is easy to produce instability phenomena such as twisting, undulation, or even "belt drifting" in the horizontal arc section, resulting in a serious lack of high-speed stability of the conveyor belt.

[0005] It is evident that current off-road belt conveyors still have room for improvement and should be optimized to enhance their load-bearing capacity and high-speed stability in horizontal arc sections, ensuring conveying capacity. This requires the use of idlers to provide corresponding functions, thus necessitating the development of more reasonable technical solutions to address the existing technical problems. Utility Model Content

[0006] To overcome the problems of insufficient load-bearing capacity and high-speed stability of conveyor belts supported by existing trough idler groups in the background art, this utility model provides a fixed upper idler for a belt conveyor. Multiple idlers are set to support the conveyor belt and the trough angle of the side idlers is increased. This has the beneficial effects of improving the load-bearing capacity and high-speed stability of the conveyor belt in the horizontal arc section, ensuring conveying capacity, significantly reducing the bending stress of the conveyor belt, and allowing the conveyor belt to transition smoothly within the idler group.

[0007] The technical solution of this utility model is as follows: A belt conveyor with fixed upper idlers includes several idler groups arranged along the transport direction. Each idler group includes a crossbeam and several idlers arranged along the crossbeam. The number of idlers in each idler group is greater than 3. The trough angle of the side idlers is greater than or equal to 45°. The conveyor belt is laid on the surface of all idlers.

[0008] Compared with existing technologies, the beneficial effects of this technical solution are as follows: Because each idler group has more than three idlers, the conveyor belt has a larger contact area with the idlers and more support points when laid within the idler group. This results in more dispersed stress, more stable load bearing, and better adaptability to high-speed operation in horizontal arc sections. This ensures high stability of the conveyor belt during operation and effectively prevents the problems of twisting, undulation, or "slipping" that easily occur when the conveyor belt turns, as seen in traditional trough idler groups used in the prior art. Furthermore, because the trough angle of the side idlers is greater than 45°, the entire idler group has a greater depth of indentation for the same width, increasing the conveyor belt's load capacity. Therefore, even with a height difference on both sides of the idler group in a horizontal arc section, the conveyor belt can carry more material compared to traditional trough idler groups, exhibiting a greater load-bearing capacity. In addition, increasing the trough angle of the side idlers also improves the support stability of the conveyor belt.

[0009] Preferably, each set of idler rollers includes a bottom idler roller located at the center, and a middle idler roller and a side idler roller are respectively provided at both ends of the bottom idler roller; the side idler roller is higher than the middle idler roller, and the middle idler roller is higher than the bottom idler roller.

[0010] Its beneficial effects are as follows: Each idler group has two side idlers on each side. Compared with the traditional trough idler group, the design of this idler group allows the conveyor belt to be bent into a curve that is closer to a natural arc. This smooth transition greatly reduces the bending stress of the conveyor belt and protects the belt body. In addition, the trough angle of the two side idlers on each side can be individually and adaptively set to more precisely balance the centrifugal force of the horizontal arc segment, ensuring that the conveyor belt is evenly stressed and will not deviate. Finally, the five-idler group design can also further improve the support stability of the conveyor belt. The conveyor belt is wrapped inside the idler group and fits more tightly with the surface of the idler, making the conveyor belt more stable at high speeds.

[0011] More preferably, the idlers of each group of idlers are distributed on the front and rear sides of the crossbeam and are arranged in a staggered manner; the ends of adjacent idlers overlap in the transport direction.

[0012] Its beneficial effects are as follows: the staggered arrangement of idlers allows the first idlers to play a preliminary guiding and centering role, while the subsequent idlers make fine adjustments, which greatly reduces the adjustment resistance of the conveyor belt, allowing it to pass through the idler group smoothly and effectively suppressing deviation, improving running stability, and distributing the support force on the conveyor belt forward and backward, which can reduce wear on the conveyor belt and improve its service life; the overlapping design allows the conveyor belt to have direct support points in the width direction, making the force on the conveyor belt in the width direction more balanced, and since the overlap only occurs at the ends of adjacent idlers, it will not cause belt jamming problems.

[0013] More preferably, both ends of the idler roller are fixedly connected to the crossbeam by support plates, and the extension direction of the support plates is parallel to the transport direction of the conveyor belt.

[0014] Its beneficial effects are as follows: The support plate is used to install the idler rollers on the front or rear side of the crossbeam. The extension direction of the support plate is parallel to the transport direction of the conveyor belt, which allows the idler roller assembly to form a smoother groove. When the conveyor belt is laid in it, the conveyor belt can bend naturally, further reducing its bending stress. In addition, it is more conducive to uniformly opening the slots on the support plate. After the support plate is fixedly installed on the crossbeam, the orientation of the slots can be perpendicular to the corresponding position of the crossbeam, so the idler roller can be stably locked in the slot without sliding out. Finally, this installation direction of the support plate is also more conducive to determining the installation angle of the support plate on the crossbeam, improving processing efficiency.

[0015] More preferably, the mounting end of the support plate is provided with a slot, and both ends of the roller shaft are inserted into the slot.

[0016] Its beneficial effects are: the slot is used to stably install the idler roller, and the idler roller rotates with the conveyor belt under the restriction of the slot.

[0017] More preferably, three rollers are arranged on one side of the crossbeam and two rollers are arranged on the other side; the length of the support plate on the side of the crossbeam where the two rollers are arranged is greater than that on the other side.

[0018] Its beneficial effect is that this arrangement allows the rollers 1 on both sides of the crossbeam along the transport direction to form a torque balance, thereby balancing the life of the support plate.

[0019] More preferably, three rollers are arranged on one side of the crossbeam and two rollers are arranged on the other side; the support plates on both sides of the crossbeam have the same length.

[0020] Its advantages are that this design can standardize all support plate specifications during mass production, which is more conducive to actual production and manufacturing.

[0021] More preferably, the groove angle of the side roller is 45°, 50°, 55° or 60°, and the groove angle of the middle roller is 25° or 30°; the two middle rollers and the two side rollers are arranged symmetrically along the center of the crossbeam.

[0022] Its beneficial effects are as follows: by setting the groove angle of the side idler, the depth of the concavity of the idler group can be further increased, which strengthens the support stability of the conveyor belt and the load-bearing capacity of the conveyor belt itself. The groove angle of the middle idler allows the conveyor belt to transition more smoothly and bend naturally. The supporting arrangement of the middle idler and the two side idlers can ensure the structural symmetry and stability of the entire idler group, and achieve more stable support for the conveyor belt.

[0023] More preferably, the crossbeam is a bent tube structure with multiple bends; side supports are also fixedly provided below the sides of the crossbeam and fixedly connected to the intermediate frame.

[0024] Its advantages are that this type of bent tube structure design makes it easier to manufacture crossbeams that meet the requirements, and the manufacturing process is simpler.

[0025] More preferably, the side support is inclined to one side of the crossbeam, and its bottom is provided with an adjustment elongated hole, which can be adapted to be fixedly connected to the intermediate frame; a reinforcing rib plate is vertically fixed to the outer side of the side support, and the upper and lower ends of the reinforcing rib plate are respectively fixedly connected to the crossbeam and the bottom of the side support.

[0026] Its beneficial effects are as follows: the side support is inclined to one side of the crossbeam, which can support the roller assembly at an angle and improve the support capacity of the side support to the crossbeam; the setting of the adjustment elongated hole makes it easy to adjust the lateral installation position of the entire roller assembly, offset manufacturing errors and prevent installation failure; the reinforcing ribs are used to enhance the rigidity and deformation resistance of the side support itself and improve its load-bearing capacity. Attached Figure Description

[0027] This utility model will be described with reference to the accompanying drawings, wherein: Figure 1 This is a three-dimensional structural diagram of the entire utility model; Figure 2 This is a front view of the entire utility model; Figure 3 This is a side view of the present invention; Figure 4 This is a top view of the present invention; Figure 5 This is a schematic diagram of the structure of the conveyor belt of this utility model laid on the idler roller.

[0028] Reference numerals: 1. Idler roller, 10. Bottom idler roller, 11. Middle idler roller, 12. Side idler roller, 13. Crossbeam, 2. Installation section, 21. Support plate, 3. Slot, 31. Side support column, 4. Adjustment elongated hole, 41. Reinforcing rib plate, 42. Conveyor belt, 5. Detailed Implementation

[0029] Example 1: As Figures 1 to 5 The belt conveyor shown includes a fixed upper idler roller, comprising several idler roller groups arranged along the transport direction. The idler roller groups are installed between intermediate frames in a horizontal arc segment and are evenly arranged along the length of the intermediate frames. Each idler roller group includes a crossbeam 2 and several idler rollers 1 arranged along the crossbeam 2. The crossbeam 2 is fixedly connected to the intermediate frame and perpendicular to the transport direction of the conveyor belt 5, and is used to install and support the idler rollers 1 and improve the overall support stability. The number of idler rollers 1 in each idler roller group is greater than 3. The side idler rollers 13 in the idler roller group are the idler rollers 1 located at the outermost edge of the crossbeam 2. The groove angle of the side idler rollers 13 is greater than or equal to 45°. The conveyor belt 5 is laid on the surface of all the idler rollers 1, and the idler rollers 1 are used to stably support the conveyor belt 5.

[0030] Because each idler group has more than three idlers 1, the conveyor belt 5 has a larger contact area with the idlers 1 when laid within the idler group, and has more support points. This results in more dispersed stress, more stable load bearing, and better adaptability to high-speed operation in horizontal arc sections. This ensures high stability of the conveyor belt 5 during operation and effectively prevents the problems of twisting, undulation, or "slipping" that easily occur when the conveyor belt 5 turns, as is common with traditional trough idler groups in the prior art. Furthermore, because the groove angle of the side idler 13 is greater than 45°, the entire idler group has a greater depth of indentation for the same width, increasing the load-bearing capacity of the conveyor belt 5. Therefore, even with a height difference on both sides of the idler group in a horizontal arc section, the conveyor belt 5 can carry more material and has a greater load-bearing capacity compared to traditional trough idler groups. In addition, increasing the groove angle of the side idler 13 also improves the support stability of the conveyor belt 5.

[0031] Example 2: Based on Example 1, the idler roller group is optimized. Each idler roller group includes a bottom idler roller 11 located in the center. A middle idler roller 12 and a side idler roller 13 are arranged sequentially at the left and right ends of the bottom idler roller 11, respectively. That is, a middle idler roller 12 and a side idler roller 13 are arranged along the crossbeam 2 at the left and right ends of the bottom idler roller 11 along the transport direction. The middle idler roller 12 is located between the side idler roller 13 and the bottom idler roller 11. Each idler roller group has a total of five idler rollers 1. Among them, the side idler 13 is higher than the middle idler 12, and the middle idler 12 is higher than the bottom idler 11. The conveyor belt 5 laid in the idler group can gradually decrease from both ends to the middle, with a smooth transition. Thus, each idler group has two side idlers on each side. Compared with the traditional trough idler group, this idler group design allows the conveyor belt 5 to be bent into a curve that is closer to a natural arc. This smooth transition greatly reduces the bending stress of the conveyor belt 5 and protects the belt body. In addition, the trough angle of the two side idlers on each side can be individually and adaptively set to more precisely balance the centrifugal force of the horizontal arc segment, ensuring that the conveyor belt 5 is evenly stressed and will not deviate. Finally, the idler group design of five idlers 1 can also further improve the support stability of the conveyor belt 5. The conveyor belt 5 is wrapped in the idler group and fits more tightly with the surface of the idler 1, making the conveyor belt 5 more stable in high-speed operation.

[0032] Preferably, all idlers 1 in each idler group are distributed on the front and rear sides of the crossbeam 2 along the transport direction, and the idlers 1 on the front and rear sides of the crossbeam 2 are staggered. The two middle idlers 12 need to be on the same side of the crossbeam 2, and the two side idlers 13 also need to be on the same side of the crossbeam 2. This design allows the first contacting idlers 1 to play a preliminary guiding and centering role, and subsequent idlers 1 to make fine adjustments, greatly reducing the adjustment resistance of the conveyor belt 5, allowing it to pass smoothly and easily through the idler group, effectively suppressing deviation, improving operational stability, and distributing the support force on the conveyor belt 5 forward and backward, reducing wear on the conveyor belt 5 and increasing its service life. Figure 5 As shown, the ends of adjacent idlers 1 overlap in the transport direction, that is, the idlers 1 on one side of the crossbeam 2 and the adjacent idlers 1 on the other side have overlapping surfaces on the bearing surface of the conveyor belt 5. This design allows the conveyor belt 5 to have direct support points in the width direction, making the force on the conveyor belt 5 more balanced in the width direction. Moreover, since the overlap only occurs at the ends of adjacent idlers 1, it will not cause the problem of belt jamming.

[0033] Preferably, both ends of the idler roller 1 are fixed to the crossbeam 2 by support plates 3, and the connecting ends of the support plates 3 are welded to the crossbeam 2. The support plates 3 on the front and rear sides of the crossbeam 2 are arranged alternately. The support plates 3 are used to install the idler roller 1 on the front or rear side of the crossbeam 2. The mounting end of the support plate 3 is provided with a slot 31. Both ends of the roller shaft 10 of the idler roller 1 are inserted into the slot 31. The slot 31 is used to stably install the idler roller 1. Under the restriction of the slot 31, the idler roller 1 rotates with the conveyor belt 5.

[0034] The extension direction of the support plate 3 is parallel to the transport direction of the conveyor belt 5. That is, the support plate 3 installed on the front side of the crossbeam 2 extends in the transport direction, while the support plate 3 installed on the rear side of the crossbeam 2 extends in the opposite direction to the transport direction. All support plates 3 are perpendicular to the crossbeam 2. This arrangement allows the idler roller assembly to form a smoother groove. When the conveyor belt 5 is laid in it, the conveyor belt 5 can bend naturally, further reducing its bending stress. In addition, it is more conducive to uniformly opening the slots 31 on the support plate 3. After the support plate 3 is fixedly installed on the crossbeam 2, the orientation of the slots 31 can be perpendicular to the corresponding position of the crossbeam 2. The idler roller 1 can be stably locked in the slots 31 without sliding out. Finally, this installation direction of the support plate 3 is also more conducive to determining the installation angle of the support plate 3 on the crossbeam 2, improving processing efficiency.

[0035] Preferably, three idler rollers 1 are arranged on one side of the crossbeam 2 along the front and rear sides of the transport direction, and two idler rollers 1 are arranged on the other side. In this embodiment, two side idler rollers 13 and bottom idler rollers 11 are on one side of the crossbeam 2, and two middle idler rollers 12 are arranged on the other side of the crossbeam 2. The length of the support plate 3 on the side of the crossbeam 2 where the two idler rollers 1 are arranged is greater than that on the other side. This arrangement allows the idler rollers 1 on the front and rear sides of the crossbeam 2 along the transport direction to form a torque balance, thereby balancing the lifespan of the support plate 3.

[0036] In another embodiment, three rollers 1 are arranged on one side of the crossbeam 2 and two rollers 1 are arranged on the other side; the support plates 3 on both sides of the crossbeam 2 have the same length, that is, the support plates 3 on the front and rear sides of the crossbeam 2 along the transport direction have the same length. This design can unify the specifications of all support plates 3 during mass production, which is more conducive to actual production and manufacturing.

[0037] In addition, the conveyor belt 5 first passes through one side of the crossbeam 2 with two idlers, and then passes through the other side with three idlers.

[0038] Example 3: Based on the above examples, the groove angle is optimized. The groove angle of the side idler 13 is 45°, 50°, 55°, or 60°, and the groove angle of the middle idler 12 is 25° or 30°. By setting the side idler 13 to a larger groove angle, the concavity depth of the idler group can be further increased, enhancing the support stability of the conveyor belt 5 and the load-bearing capacity of the conveyor belt 5 itself. Specifically, when the groove angle of the side idler 13 is 45° or 50° and the groove angle of the middle idler 12 is 25°, and when the groove angle of the side idler 13 is 55° or 60° and the groove angle of the middle idler 12 is 30°, this arrangement allows the conveyor belt 5 to transition more smoothly and bend naturally. In addition, when the groove angle of the side idler 13 is 45°, 50°, or 55°, it can also be used as a general transition idler, thus broadening the application range of the idler group.

[0039] The two central idler rollers 12 and the two side idler rollers 13 are arranged symmetrically along the center of the crossbeam 2, which can ensure the structural symmetry and stability of the entire idler roller group and achieve more stable support for the conveyor belt 5.

[0040] Example 4: Based on the above examples, the crossbeam 2 is optimized. The crossbeam 2 is a bent tube structure with multiple bends, forming a groove structure. The crossbeam 2 is bent 4 times, forming a total of five installation sections 21 for mounting the idler rollers 1. The 5 idler rollers 1 are connected to the corresponding installation sections 21 in parallel through support plates 3. The inclination angle of each installation section 21 needs to be adapted to the groove angle to be formed by the corresponding idler roller 1. The crossbeam 2 can be formed by connecting multiple steel pipes or by bending a single rigid tube four times. This bent tube structure design makes it easier to manufacture the crossbeam 2 that meets the requirements, and the manufacturing process is simpler.

[0041] Side supports 4 are welded and fixed to the lower part of the left and right sides of the crossbeam 2 along the transport direction and are fixedly connected to the intermediate frame. The side supports 4 are used to support the entire idler assembly and to install and connect the idler assembly to the intermediate frame. Specifically, the side supports 4 are inclined to one side of the crossbeam 2 to support the idler assembly at an angle, which can improve the support capacity of the side supports 4 for the crossbeam 2.

[0042] The bottom of the side support 4 is provided with an adjustment elongated hole 41, which can be adapted to be fixedly connected to the intermediate frame. The adjustment elongated hole 41 extends along the width direction of the conveyor belt 5, which facilitates the adjustment of the lateral installation position of the entire idler assembly, compensates for manufacturing errors, and prevents installation failure. A reinforcing rib plate 42 is vertically fixed to the middle of the outer side of the side support 4 along its length. The upper and lower ends of the reinforcing rib plate 42 are fixedly connected to the crossbeam 2 and the bottom of the side support 4, respectively. The reinforcing rib plate 42 is used to enhance the rigidity and deformation resistance of the side support 4 and improve its load-bearing capacity.

[0043] The above embodiments merely illustrate specific implementation methods of this application, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of protection of this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the technical solution of this application, and these all fall within the scope of protection of this application.

Claims

1. A fixed upper idler roller for a belt conveyor, comprising a plurality of idler roller groups arranged along the transport direction, characterized in that: Each set of idler rollers includes a crossbeam (2) and several idler rollers (1) arranged along the crossbeam (2). The number of idler rollers (1) in each set of idler rollers is greater than 3. The groove angle of the side idler rollers (13) is greater than or equal to 45°. The conveyor belt (5) is laid on the surface of all idler rollers (1). The idler rollers (1) in each set of idler rollers are distributed on the front and rear sides of the crossbeam (2) and are staggered. The ends of adjacent idler rollers (1) overlap in the transport direction.

2. A fixed upper idler roller for a belt conveyor according to claim 1, characterized in that: Each set of idler rollers includes a bottom idler roller (11) located in the center, and a middle idler roller (12) and a side idler roller (13) are respectively arranged at both ends of the bottom idler roller (11); the side idler roller (13) is higher than the middle idler roller (12), and the middle idler roller (12) is higher than the bottom idler roller (11).

3. A fixed upper idler roller for a belt conveyor according to claim 1, characterized in that: The two ends of the idler roller (1) are fixedly connected to the crossbeam (2) by support plates (3), and the extension direction of the support plates (3) is parallel to the transport direction of the conveyor belt (5).

4. A fixed upper idler roller for a belt conveyor according to claim 3, characterized in that: The mounting end of the support plate (3) is provided with a slot (31), and both ends of the roller shaft (10) of the roller (1) are inserted into the slot (31).

5. A fixed upper idler roller for a belt conveyor according to claim 3, characterized in that: Three rollers (1) are arranged on one side of the crossbeam (2) and two rollers (1) are arranged on the other side; the length of the support plate (3) on the side where the two rollers (1) are arranged on the crossbeam (2) is greater than that on the other side.

6. A fixed upper idler roller for a belt conveyor according to claim 3, characterized in that: Three rollers (1) are arranged on one side of the crossbeam (2) and two rollers (1) are arranged on the other side; the support plates (3) on both sides of the crossbeam (2) have the same length.

7. A fixed upper idler roller for a belt conveyor according to claim 2, characterized in that: The groove angle of the side roller (13) is 45°, 50°, 55° or 60°, and the groove angle of the middle roller (12) is 25° or 30°; the two middle rollers (12) and the two side rollers (13) are arranged symmetrically along the center of the crossbeam (2).

8. A fixed upper idler roller for a belt conveyor according to claim 1 or claim 7, characterized in that: The crossbeam (2) is a bent tube structure with multiple bends; side support columns (4) are also fixedly installed on the lower sides of both sides of the crossbeam (2) and fixedly connected to the intermediate frame.

9. A fixed upper idler roller for a belt conveyor according to claim 8, characterized in that: The side support (4) is inclined to the side of the crossbeam (2), and its bottom is provided with an adjustment elongated hole (41). The adjustment elongated hole (41) can be adapted to be fixedly connected to the intermediate frame. A reinforcing rib plate (42) is vertically fixed on the outside of the side support (4). The upper and lower ends of the reinforcing rib plate (42) are fixedly connected to the bottom of the crossbeam (2) and the side support (4), respectively.

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