Belt Conveyor Idler Roller Replacement Without Lowering the Belt
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Solution Overview
Problem
Existing methods for replacing idler rollers in belt conveyor systems are inefficient due to the high weight and size of the rollers, requiring additional aids and limiting manual replacement, especially in large mass flow systems where occupational safety concerns restrict manual intervention.
Innovation Solution
A process and device involving a subframe and changing frame, lifted by an external apparatus, allows for the removal and replacement of individual idler rollers without lowering the conveyor belt, using a subframe to suspend the belt and a changing frame to pick up and replace rollers, reducing the need for multiple lifting apparatuses and enabling rapid replacement across long conveyor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual replacement of idler rollers is attempted, then labor cost is reduced, but occupational safety is compromised and replacement is only allowed in resting state
Solution Approach 1:
The patent introduces a replacement device as an intermediary tool between the operator and the idler roller. This device includes a lifting mechanism that suspends the heavy idler roller, allowing safe manual handling and replacement without direct manual lifting, thus maintaining occupational safety while enabling manual replacement operations
Solution Approach 2:
The replacement device is designed to be positioned and prepared in advance at the conveyor location. The lifting mechanism is pre-assembled and ready to suspend the idler roller before the actual replacement begins, allowing the conveyor to remain operational during the preparation phase and eliminating the need to stop the entire system for safety
2Reliability
If entire idler roller girlands are replaced, then replacement completeness is ensured, but replacement time and labor effort increase
Solution Approach 1:
The replacement device is designed to handle individual idler rollers separately rather than requiring replacement of entire girlands. The lifting mechanism can suspend and position single rollers, allowing selective replacement of only the defective units while leaving functional rollers in place, thus reducing replacement time and labor effort while maintaining replacement completeness for affected areas
Solution Approach 2:
The device enables localized replacement at specific problem areas along the conveyor system. Each replacement operation can be independently performed at different locations without affecting other areas, allowing targeted maintenance that replaces only the necessary components rather than entire assemblies
3Ease of operation
If multiple lifting apparatuses are used, then belt suspension capability is improved, but device complexity and cost increase
Solution Approach 1:
The replacement device incorporates a multi-functional lifting mechanism that can perform multiple operations with a single apparatus. The same lifting mechanism suspends the belt, supports the idler roller during replacement, and facilitates positioning of the roller back onto the belt, eliminating the need for multiple separate lifting devices and reducing overall system complexity
Solution Approach 2:
The patent combines several lifting functions into a single integrated replacement device. The lifting mechanism is merged with the roller support and positioning systems, creating a unified apparatus that performs all necessary suspension and replacement operations, thereby reducing device complexity and cost while maintaining full belt suspension capability
Data Source
AI summary
A method and a device are provided for replacing individual idler rollers for conveyors, with which a web belt can be lifted and worn-out or damaged idler rollers in upper and lower runs can be individually replaced. The device includes, separately for replacing the idler rollers in the upper run and in the lower run, a subframe (1) for lifting the web belt (7) and for holding the web belt (7), such that a sufficient clearance is formed for replacing worn-out idler rollers (53) by means of a changing frame (2). A service vehicle is equipped with a lifting apparatus for moving dividing devices. The process steps include lifting the web belt (7), removing the old idler roller (53old), inserting the new idler roller (53new) and lowering the web belt (7). The drawing shows the use of two dividing devices in the replacing of idler rollers in the upper run.