Method for replacing the frame of a belt conveyor

Abstract

To provide a replacement method of a frame of a belt conveyor capable of replacing the frame without cutting nor re-connecting a conveyor belt.SOLUTION: A replacement method of a frame of a belt conveyor comprises: a conveyor belt which is formed into an annular shape and has an upper belt disposed in an upward direction and a lower belt disposed in a downward direction; and a frame for supporting the conveyor belt. The replacement method of the frame of the belt conveyor includes: a lower belt holding step for holding the lower belt to move it upward; a lower space generation step in which a constituent member of the frame supporting the lower belt is removed to release the holding of the lower belt; an upper space generation step in which the upper belt is held to be moved to the upper part of the frame; and a replacement step in which the constituent member of the frame is changed over to replace the frame.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for replacing a frame of a belt conveyor.

Background Art

[0002] In the conventional work of replacing the frame of a belt conveyor, cutting of the conveyor belt, replacement of the frame, and reconnection of the cut conveyor belt are performed. When performing the frame replacement work, the operation of the equipment must be stopped. For this reason, it is required that the frame replacement work be performed in a short time.

[0003] Particularly, cutting and reconnection of the conveyor belt require a lot of time. Therefore, conventionally, consideration has been given to performing the frame replacement work without cutting and reconnecting the conveyor belt. For example, in Patent Document 1, the upper belt arranged on the upper side of the conveyor belt and the lower belt arranged on the lower side are gripped and lifted upward, at least a part of the frame is removed, and a new frame is installed at the removed location.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, the method for updating the frame of the belt conveyor described in Patent Document 1 may be difficult to apply depending on the tension applied to the conveyor belt.

[0006] Specifically, the conveyor belt is tensioned so as to have an appropriate amount of slack. When the length of the slack of the conveyor belt is short, even if the tension is released and the upper belt and the lower belt are lifted upward, there is a problem that it is difficult to secure the space necessary for the frame replacement work.

[0007] The present invention has been made in view of the above problems, and an object thereof is to provide a method for replacing a frame of a belt conveyor that can replace the frame without cutting and reconnecting the conveyor belt.

Means for Solving the Problems

[0008] In order to solve the above problems, the present invention has the following features.

[0009] [1] A method for replacing a frame of a belt conveyor having a conveyor belt formed in an annular shape and having an upper belt arranged upward and a lower belt arranged downward, and a frame that supports the conveyor belt, comprising: a lower belt gripping step of gripping the lower belt and moving it upward; a lower space generation step of removing a constituent member of the frame that supports the lower belt and releasing the gripping of the lower belt; an upper space generation step of gripping the upper belt and moving it above the frame; a replacement step of replacing the constituent members of the frame to replace the frame; A method for replacing a frame of a belt conveyor, comprising: [2] The upper space generation step includes: a support portion installation step of installing a support portion that supports the upper belt extending upward above the frame; a support step of supporting the upper belt by the support portion; The method for replacing a frame of a belt conveyor according to [1], comprising: [3] The support portion is attached to a constituent member of the frame that supports the upper belt, or The support portion is fixed to the floor surface to which a support column that supports the frame is fixed. A method for replacing a frame of a belt conveyor according to [2]. [4] The belt conveyor has a tension applying portion that applies tension to the conveyor belt. By the lower space generation step and the upper space generation step, the conveyor belt moves vertically by a length corresponding to the margin stroke of the tension applying portion. A method for replacing a frame of a belt conveyor according to any one of [1] to [3]. [5] The constituent member of the frame that supports the lower belt includes a pair of leg portions arranged in the width direction of the conveyor belt, a horizontal member that connects the pair of leg portions, a first diagonal member that connects one of the pair of leg portions and the horizontal member, a second diagonal member that connects the other of the pair of leg portions and the horizontal member, and a return roller that supports the conveyor belt provided so as to span between the pair of leg portions. In the replacement step, after the return roller is attached, the horizontal member, the first diagonal member, and the second diagonal member are attached. A method for replacing a frame of a belt conveyor according to any one of [1] to [4].

Advantages of the Invention

[0010] According to the method for replacing a frame of a belt conveyor of the present invention, by having a lower space generation step and an upper space generation step, the upper belt and the lower belt move away from each other. Thereby, a wider working space can be secured than when the upper belt and the lower belt are moved in the same direction. Therefore, it becomes possible to perform the work of replacing the conveyor frame without cutting and reconnecting the conveyor belt.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

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Figure 8

Figure 9

Figure 10

Mode for Carrying Out the Invention

[0012] Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 shows the overall configuration of the belt conveyor. As shown in FIG. 1, the belt conveyor 100 has an annular conveyor belt 10 and a frame 20 that supports the conveyor belt 10.

[0013] The conveyor belt 10 has an upper belt 11 arranged upward and a lower belt 12 arranged downward. As the conveyor belt 10, for example, a rubber belt can be used. The conveyor belt 10 is conveyed in the conveying direction D1. Note that the conveying direction D1 is not particularly limited, and the direction opposite to the direction shown in FIG. 1 may be used as the conveying direction.

[0014] In the conveying direction D1, the columns 21 are arranged at a predetermined interval (for example, 12 m). The frame 20 is installed between adjacent columns 21. The frame 20 has, for example, a three-dimensional truss structure formed by assembling H-shaped steel into a truss shape. Incidentally, the frame 20 is not particularly limited, but for example, the height can be 1.2 m. The installation height of the frame 20 is not particularly limited as long as it can provide a work passage WP described later, but for example, it can be installed at a height of 1 m above the ground.

[0015] The frame 20 has a head pulley 22 provided on the downstream side in the conveying direction D1 of the conveyor belt 10 and a tail pulley 23 provided on the upstream side in the conveying direction D1 of the conveyor belt 10. The conveyor belt 10 is wound around the head pulley 22 and the tail pulley 23.

[0016] On the downstream side in the conveying direction D1 of the conveyor belt 10 of the frame 20, a gravity tensioning device 30 is provided as a tension applying portion for applying tension to the conveyor belt 10.

[0017] The gravity tensioning device 30 has a pair of gravity snap pulleys 31 for applying tension to the conveyor belt 10 and a gravity pulley 32 provided between the pair of gravity snap pulleys 31.

[0018] In the present embodiment, the conveyor belt 10 is in contact with the gravity snap pulley 31 provided on the head pulley 22 side on the front surface (outer surface), and is in contact with the gravity snap pulley 31 provided on the tail pulley 23 side on the back surface (inner surface). Further, the conveyor belt 10 is in contact with the gravity pulley 32 on the back surface (inner surface).

[0019] The gravity pulley 32 is provided so as to be movable in a direction approaching and a direction separating from the pair of gravity snap pulleys 31. The gravity pulley 32 is connected to a weight 34 by a rope 33. The weight 34 is connected to the gravity pulley 32 via a pulley 35.

[0020] Therefore, when the weight of the weight 34 is reduced, the gravity pulley 32 moves in a direction approaching the pair of gravity snap pulleys 31. Also, when the weight of the weight 34 is increased, the gravity pulley 32 moves in a direction away from the pair of gravity snap pulleys 31. By such an operation, the tension applied to the conveyor belt 10 and the slack amount of the conveyor belt 10 are adjusted. Incidentally, when releasing the tension applied to the conveyor belt 10, it can be performed by raising the weight 34 using a chain block or the like. Note that the structure of the gravity tensioning device 30 is not limited to that described above. For example, a structure in which the weight 34 is directly suspended from the belt conveyor via the gravity pulley 32 at the position of the raised floor may be used. Also, the structure of the gravity tensioning device 30 may have other structures and is not particularly limited.

[0021] FIG. 2 schematically shows the configuration of the belt conveyor 100 as viewed from the front. As shown in FIG. 2, the frame 20 has a pair of leg portions 24 arranged in the width direction D2 of the conveyor belt 10. The frame 20 includes a horizontal member 25 connecting the pair of leg portions 24, a first diagonal member 26a connecting one leg portion 24 and the horizontal member 25, and a second diagonal member 26b connecting the other leg portion 24 and the horizontal member 25. The frame 20 has a return roller 27 that supports the lower belt 12 provided so as to span between the pair of leg portions 24, and a carrier roller unit 28 that supports the upper belt 11 provided so as to span between the pair of leg portions 24. Incidentally, the frame 20 may be provided with a work passage WP for inspection or the like on both sides in the width direction D2 of the conveyor belt 10. Also, the members constituting the frame 20 are not limited to these members and can be provided as appropriate.

[0022] The carrier roller unit 28 has carrier rollers 28a, 28b, 28c and a carrier roller base 28d that supports the carrier rollers 28a, 28b, 28c. The carrier roller 28a is arranged on one end side in the width direction D2 of the conveyor belt 10 in the frame 20. The carrier roller 28a is arranged to be inclined such that the height decreases from one end side to the other end side in the width direction D2 of the conveyor belt 10.

[0023] The carrier roller 28c is arranged on the other end side in the width direction D2 of the conveyor belt 10 in the frame 20. The carrier roller 28c is arranged to be inclined such that the height decreases from the other end side to the one end side in the width direction D2 of the conveyor belt 10.

[0024] The carrier roller 28b is arranged between the carrier roller 28a and the carrier roller 28b. The carrier roller 28b is provided along the width direction D2 of the conveyor belt 10.

[0025] The carrier rollers 28a, 28b, 28c are formed in a concave shape so as to form a U shape when viewed from the front. Therefore, when the upper belt 11 is placed on the carrier rollers 28a, 28b, 28c, the upper belt 11 becomes a U shape along the shape of the carrier rollers 28a, 28b, 28c. Thereby, it is possible to prevent the conveyed object from falling in the width direction D2 of the conveyor belt 10.

[0026] On the other hand, the return roller 27 is composed of one member and is provided along the width direction D2 of the conveyor belt 10. Therefore, when the lower belt 12 is placed on the return roller 27, the lower belt 12 becomes a flat shape along the shape of the return roller 27.

[0027] Figure 3 shows the flow of the method for replacing the frame of the belt conveyor. As shown in Figure 3, the method for replacing the frame of the belt conveyor first grips the lower belt 12 and moves it upward (step S01).

[0028] When the lower belt gripping step of step S01 is performed, the constituent members of the frame 20 that support the lower belt 12 are removed, and the gripping of the lower belt 12 is released (step S02). Note that, as the constituent members of the frame 20 removed in the lower space generation step of step S02, there are the horizontal member 25, the first diagonal member 26a, the second diagonal member 26b, and the return roller 27.

[0029] When the lower space generation step of step S02 is performed, the upper belt 11 is gripped and moved above the frame 20 (step S03).

[0030] When the upper space generation step of step S03 is performed, an exchange step is performed in which the constituent members of the frame 20 are replaced and the frame is exchanged (step S04).

[0031] FIG. 4 shows a mode in which the lower belt gripping step of step S01 is performed. As shown in FIG. 4, in the lower belt gripping step of step S01, first, the weight 34 of the gravity tensioning device 30 is lifted using a gripping means such as a chain block to release the tension acting on the conveyor belt 10. Next, for example, the lower belt 12 is fixed by winding it around an existing conveyor with a belt sling rope or the like, and the lower belt 12 is moved upward by moving the rope upward. At that time, it is preferable to move it upward to a position where the lower belt 12 does not contact the return roller.

[0032] FIG. 5 shows a mode in which the return roller 27 is removed in the lower space generation step of step S02. FIG. 6 shows a mode in which a constituent member of the frame 20 that supports the lower belt 12 is removed in the lower space generation step of step S02. FIG. 7 shows a mode of the frame 20 when the belt conveyor 100 is viewed from the front. As shown in FIGS. 5 to 7, after the return roller 27 that supports the lower belt 12 is removed, the horizontal member 25, the first diagonal member 26a, and the second diagonal member 26b are cut. At this time, the work passage WP may also be cut. Next, the gripping state of the lower belt 12 is released, and the lower belt 12 sags under its own weight.

[0033] FIG. 8 shows a mode in which the upper belt 11 is moved above the frame 20 in the upper space generation step of step S03. As shown in FIG. 8, the upper belt 11 is, for example, gripped by a mobile crane (not shown) and lifted upward. As a result, the conveyor belt 10 moves in the vertical direction by the amount of the surplus stroke of the gravity tensioning device 30. In other words, the conveyor belt 10 moves in the vertical direction by a length corresponding to the tension applied by the gravity tensioning device 30.

[0034] The height H1 between the upper belt 11 and the lower belt 12 is preferably made higher than the height H2 of the frame 20. By doing so, it becomes possible to secure a sufficient space for replacement work.

[0035] Note that the height H1 between the upper belt 11 and the lower belt 12 is not particularly limited, but can be, for example, 1.5 m. Also, the height H2 of the frame 20 is preferably up to the maximum belt surplus length of the gravity tensioning device 30. The height H2 of the frame 20 is not particularly limited, but can be, for example, 1.2 m.

[0036] Next, a pair of support portions 40 that support the upper belt 11 are provided on the frames 20 located on the upstream side and the downstream side of the frame 20 to be replaced in the conveyance direction D1 of the belt conveyor 100.

[0037] The support part 40 is formed to extend upward from the frame 20. Specifically, the support part 40 has a column part 41 formed in a column shape and an umbrella part 42 formed at an acute angle with the column part 41. The column part 41 is provided across the frame 20 in the width direction D2 of the conveyor belt 10. The column part 41 is fixed to the frame 20 by fastening members such as bolts and nuts, for example. Incidentally, the column part 41 may be formed such that the height H1 between the upper belt 11 and the lower belt 12 is longer than the height H2 of the frame 20. Also, the column part 41 may be configured to be telescopically adjustable in its height direction.

[0038] The umbrella part 42 is formed to be inclined so that the height decreases from the tip side of the column part 41 toward the upstream side or the downstream side in the conveying direction D1 of the belt conveyor 100. The umbrella part 42 is formed across the width direction D2 of the conveyor belt 10.

[0039] Therefore, by placing the upper belt 11 on the support part 40, the height H1 between the upper belt 11 and the lower belt 12 is maintained. Thereby, the gripping state of the upper belt 11 by the mobile crane can be released. Also, since the support part 40 supports the upper belt 11, it is possible to eliminate the work under the suspended load and ensure the safety of the operator. Also, by forming the support part 40 so that it can be fixed to the frame 20, the existing equipment can be utilized, so the cost can be reduced.

[0040] FIG. 9 shows an aspect of the replacement step of step S04. As shown in FIG. 9, all of the existing frames 20 are removed. When removing the existing frame 20, each member may be disassembled or each member may be removed all at once.

[0041] After that, install the newly assembled new frame 20. The new frame 20 may be in a state where the constituent members of the frame 20 that support the lower belt 12 (the horizontal member 25, the first diagonal member 26a, and the second diagonal member 26b) are removed. After that, the service passage WP may be assembled.

[0042] Note that the shape of the newly installed frame 20 may become unstable during transportation by the crane. For this reason, during transportation by the crane, it is advisable to temporarily support it with a chain block or the like to prevent the inclination of the work passage WP. In addition, the newly installed frame 20 may be provided with a rod-shaped temporary horizontal member (not shown) that connects the legs 24 at the lower part to stabilize the shape during the transportation. One or more temporary horizontal members can be provided in the conveying direction D1 of the belt conveyor 100.

[0043] Next, remove the support portion 40, place the upper belt 11 on the carrier rollers 28a, 28b, 28c, remove the temporary horizontal member from the newly installed frame 20, and place the lower belt 12 on the return roller 27. Note that a rope such as a belt sling can be used for attaching the lower belt 12.

[0044] Next, assemble the constituent members of the frame 20 that support the lower belt 12 (the horizontal member 25, the first diagonal member 26a, and the second diagonal member 26b). Finally, release the chain block attached to the walkway member, introduce tension into the gravity tensioning device 30, and apply tension to the conveyor belt 10. That is, after the return roller 27 is attached, the horizontal member 25, the first diagonal member 26a, and the second diagonal member 26b are attached, so that a sufficient working space can be secured and the working efficiency can be improved.

[0045] As described above, according to the method for replacing the frame of the belt conveyor 100 of the present invention, by having the lower space generation step (step S02) and the upper space generation step (step S03), the upper belt 11 and the lower belt 12 move away from each other. Thereby, a wider working space can be secured than in the conventional method of moving the upper belt 11 and the lower belt 12 in the same direction. Specifically, the surplus length of the conveyor belt 10 required to provide the space can be made half the length compared to the conventional method. Therefore, it becomes possible to perform the replacement work of the frame 20 without cutting and reconnecting the conveyor belt 10.

[0046] Also, since the frame 20 with the carrier rollers 28a, 28b, 28c pre-installed can be attached, there is no need to perform the work of attaching them after installing the frame 20. For this reason, the work efficiency can be improved and the work time can be shortened.

[0047] In addition, in the present embodiment, an example in which the lower space generation step and the upper space generation step are performed in this order has been described. However, either of the two steps may be performed first. For example, the upper space generation step and the lower space generation step may be performed in this order. Also, the lower space generation step and the upper space generation step may be performed simultaneously.

[0048] In addition, in the present embodiment, an example in which the support portion 40 is fixed to the frame 20 has been described. The support portion 40 is not limited to such a mode, and may be fixed to the ground (floor surface) to which the support column 21 that supports the frame 20 is fixed.

[0049] Figure 10 shows another embodiment of the support portion. As shown in Figure 10, the support portion 50 may be fixed to the ground (floor surface), for example, at a position adjacent to the support column 21. By providing the support portion 50 in this way, it becomes possible to install the support portion 50 regardless of the shape of the frame 20. In addition, in this embodiment, although the method of replacing the frame of the belt conveyor 100 using the support portions 40 and 50 has been described, the support portions 40 and 50 are members that can be used arbitrarily. Therefore, the method of replacing the frame of the belt conveyor 100 may be implemented without using the support portions 40 and 50.

[0050] Furthermore, the method of replacing the frame of the belt conveyor 100 of the present invention is particularly preferably implemented for the low-floor belt conveyor 100, but is not particularly limited. The method of replacing the frame of the belt conveyor 100 of the present invention can also be applied to other types of belt conveyors 100 as long as a work space for performing the replacement work can be secured.

Explanation of Reference Numerals

[0051] 100 Belt conveyor 10 Conveyor belt 20 Frame 24 Legs 25 Horizontal member 26a First diagonal member 26b Second diagonal member 27 Return roller 28 Carrier roller unit 28a, 28b, 28c Carrier roller 28d Carrier roller stand 30 Tension applying portion (gravity tensioning device) 40 Support portion 50 Support portion

Claims

1. A method for replacing the frame of a belt conveyor, comprising a conveyor belt having an upper belt formed in a ring shape and arranged upward and a lower belt arranged downward, and a frame for supporting the conveyor belt, a lower belt gripping step of gripping the lower belt and moving it upward; a lower space generating step of removing a constituent member of the frame that supports the lower belt and releasing the gripping of the lower belt; an upper space generating step of gripping the upper belt and moving it above the frame; a replacement step of replacing the frame by replacing the constituent members of the frame; A method for replacing the frame of a belt conveyor, comprising the steps above.

2. The method for replacing the frame of a belt conveyor according to claim 1, wherein the upper space generating step is performed by installing a support portion that supports the upper belt extending upward above the frame and supporting the upper belt with the support portion.

3. The support portion is attached to a constituent member of the frame that supports the upper belt, or The method for replacing the frame of a belt conveyor according to claim 2, wherein the support portion is fixed to a floor surface to which a support column that supports the frame is fixed.

4. The belt conveyor has a tension applying portion for applying tension to the conveyor belt, In the lower space generating step and the upper space generating step, the conveyor belt moves up and down by a length corresponding to the margin stroke of the tension applying portion. The method for replacing the frame of a belt conveyor according to any one of claims 1 to 3.

5. The constituent member of the frame that supports the lower belt includes a pair of leg portions arranged in the width direction of the conveyor belt, a horizontal member connecting the pair of leg portions, a first diagonal member connecting one of the pair of leg portions and the horizontal member, a second diagonal member connecting the other of the pair of leg portions and the horizontal member, and a return roller for supporting the conveyor belt provided so as to span between the pair of leg portions. In the replacement step, after the return roller is attached, the horizontal member, the first diagonal member, and the second diagonal member are attached. The method for replacing the frame of a belt conveyor according to any one of claims 1 to 3.

6. The constituent members of the frame that support the lower belt include a pair of leg portions arranged in the width direction of the conveyor belt, a horizontal member that connects the pair of leg portions, a first diagonal member that connects one of the pair of leg portions and the horizontal member, a second diagonal member that connects the other of the pair of leg portions and the horizontal member, and a return roller that supports the conveyor belt provided so as to span between the pair of leg portions. The method for replacing the frame of the belt conveyor according to claim 4, wherein in the replacement step, after the return roller is attached, the horizontal member, the first diagonal member, and the second diagonal member are attached.

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