Service Vehicle for Conveyor Idler Replacement in Tunnels
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Solution Overview
Problem
In conveyor belt systems with large belt widths and high conveying speeds, individual idlers become too heavy to be replaced by maintenance personnel without additional auxiliary means, and existing idler replacement devices require significant space that is often not available, especially in long tunnel sections.
Innovation Solution
A service vehicle with a gate-like frame, driven track running gear, a horizontally pivoting platform, and an idler garland with a lifting apparatus, allowing for idler replacement in spatially limited areas by enclosing the belt conveyor and using a positive-locking drive system to maintain stability and access on steep routes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If auxiliary devices are used for replacing idlers, then idler replacement becomes possible, but significant space is required next to and above the belt conveyor
Solution Approach 1:
The service vehicle encloses the belt conveyor in a gate-like manner, with the frame structure nesting around the conveyor. The platform is accommodated within the frame, and the lifting apparatus is integrated into the platform structure, creating a compact nested arrangement that minimizes space requirements while maintaining full idler replacement capability.
Solution Approach 2:
The service vehicle transitions from requiring lateral space to operating within a vertical envelope by enclosing the conveyor in a gate-like structure. The platform can be positioned at different heights along the conveyor route, utilizing the vertical dimension rather than requiring extensive horizontal space next to the conveyor.
2Ease of operation
If cable line drive is used for the replacing device, then the device can be displaceable, but it is only suitable for shorter conveying sections
Solution Approach 1:
The cable line drive is replaced with a positive-locking drive system that engages directly with the tracks. This substitution eliminates the limitations of cable line drives, enabling the service vehicle to operate reliably on longer conveying sections while maintaining displaceability and stability on steep terrain.
3Ease of operation
If sufficient free space is provided for idler replacement, then idler replacement can be performed, but the space requirement increases
Solution Approach 1:
The platform is made movable and adjustable, capable of being positioned at different locations along the conveyor route and adjusted to maintain a horizontal working position regardless of the conveyor's slope. This dynamic positioning capability provides adequate working space for idler replacement without requiring permanent fixed space installations.
Data Source
AI summary
A track displaceable service vehicle replaces individual worn or damaged idlers with new idlers in the upper run and lower run of a belt conveyor with rising or falling conveying route, in which there is little space for the use of the service vehicle for replacing the idlers. The service vehicle accommodates a magazine for new and worn idlers and auxiliary devices for lifting the belt and removing old and for installing new idlers. A platform carries service personnel, and can be brought into a horizontal position in case of an inclined travel route of the service vehicle. The replacing of worn or defective idlers takes place in certain cycles in which the entire segment of the belt conveyor is removed and all worn and defective idlers are replaced. The service vehicle has a drive and is suitable for long tunnel sections (conveying routes which extend over several kilometers).