AU2020233738A1 - A conveyor idler roller for a transport conveyor - Google Patents

Abstract

A conveyor idler roller for a transport conveyor, the conveyor idler roller comprising a pair of end caps, each end cap pair member positioned at an opposite end of a conveyor idler roller housing for retaining a bearing pair member and a stub axle pair member at each end of the conveyor idler roller housing; and a connecting rod wherein each end of the connecting rod passes through an aperture of each stub axle pair member and is retained in each stub axle to fix the position of each stub axle pair member with respect to each other. 2/9 100 104 - 128 116 114 110 106 108 102 126 1180 120 Figure 2

Description

2/9

100 104 - 128 116 114

110 106 108 102

126 1180

120

Figure 2

A CONVEYOR IDLER ROLLER FOR A TRANSPORT CONVEYOR TECHNICAL FIELD

[0001] The present invention relates to idler rollers and, more particularly, to an axle assembly for conveyor idler rollers used in belt conveyors for bulk materials handling.

BACKGROUND ART

[0002] Referring to figure 1, conveyor idler rollers 10 are an integral part of transport conveyor 12, because they support the conveyor belt 14 that travels over them. The conveyor belt 14 is used for carrying materials 16. Conveyor idler rollers 10 commonly comprise a cylindrical conveyor idler roll tube housing 18 that has an end cap 20 at each end that in tum holds an axle 22 that passes through them from one end of the housing 18 to the other end in a so called "through shaft" conveyor idler roller (see figure 2).

[0003] Each end of the axle 22 is held in place in a separate slot 24 situated on a conveyor idler support frame 26. The end caps 20 house bearings (not shown) through which the axle 22 passes and they in tum rotate in the housing 18 around the axle. The axle 22 is stationary and each end is fixed into place in the slot 24 of the support frame 26.

[0004] Conveyors are commonly used to transport a wide range of materials (such as minerals including coal, iron ore, phosphate or bauxite) through various stages of the transport chain, commonly between a pit and the loading of ships at port. They are also used for agricultural purposes including for the transport of grain to and from silos.

[0005] As the output of mining and farming operations has increased, so to have the size of the conveyors, the width, length and weight of the conveyor belts, and the speed at which the materials pass along the belts from one end of the conveyor to the other end before the materials are discharged.

[0006] Conveyer idler roller failure can result in unplanned stoppages and lost production. In addition, frequent failures can require stocking higher inventory levels to service the conveyer. Conveyer idler roller failure can also result in belts and other conveyer components. The ability to replace failed rollers by replacing them with functional rollers efficiently minimises down time in lost production. In addition, extending the operation life of rollers before replacement increases production capacity.

[0007] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

OBJECT OF THE INVENTION

[0008] It is an object of the present invention to provide an improved conveyor idler roller for a transport conveyer that addresses or at least ameliorates the aforementioned disadvantages or provides a useful choice.

SUMMARY OF INVENTION

[0009] The present invention in its broadest form provides for fixing of the relative position of a pair of stub axle pair members with respect to one another in a conveyor idler roller to facilitate easier fitting of the conveyor idler roller in a conveyor idler support frame by enabling synchronization of the position of each stub axle to enable simultaneous insertion of each stub axle in a respective slot situated on the conveyor idler support frame. This obviates the need to independently orientate each stub axle at each end of the roller housing before fitting into each respective slot.

[0010] According to a first aspect of the present invention, there is provided a conveyor idler roller for a transport conveyor, the conveyor idler roller comprising:

• a pair of roller end cap, each roller head positioned at an opposite end of a roller housing for retaining a bearing pair member and a stub axle pair member at each end of the roller housing; and

• a connecting rod

wherein each end of the connecting rod passes through an aperture of each stub axle pair member and is retained in each stub axle to fix the position of each stub axle pair member with respect to each other.

[0011] Preferably, the connecting rod is manufactured from steel.

[0012] Preferably, each end of the connecting rod is retained in each stub axle by welding.

[0013] Preferably, each stub axle pair member comprises a broach configured to be retained in a conveyor idler roller support frame to support each end of the conveyor idler roller. In this way each broach of the stub axle pair member is aligned with respect to each other to facilitate efficient fitting of a conveyor idler roller to the conveyor idler roller support frame.

[0014] According to a second aspect of the present invention, there is provided a method of manufacture of a conveyor idler roller for a transport conveyor, wherein the method comprising the steps:

a. drilling an aperture in a pair of stub axles;

b. extending a connecting rod through a conveyor idler roller housing and the aperture in each of the stub axle pair members; and

c. retaining each end of the connecting rod in each of the stub axle pair members.

[0015] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

BRIEF DESCRIPTION OF DRAWINGS

[0016] Various embodiments of the invention will be described with reference to the following drawings, in which:

[0017] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0018] Figure 1 is a perspective view of a known belt conveyor used in bulk materials handling for use with the conveyor idler roller.

[0019] Figure 2 is an exploded view of a first embodiment the conveyor idler roller of the present invention for use with the belt conveyor of figure 1.

[0020] Figure 3 is a perspective sectional view of an end cap of thefirst embodiment from Figure 2.

[0021] Figure 4 is a perspective sectional view of an end cap of a second embodiment of the present invention.

[0022] Figure 5 is a photographic perspective view of a pair of conveyor idler roller end caps connected by an axle.

[0023] Figure 6 is a photographic close-up view of the end cap of Figure 5 connected by an axle.

[0024] Figure 7 is a photographic end view of the end cap of Figure 5.

[0025] Figure 8 is a perspective view of a third embodiment the conveyor idler roller.

[0026] Figure 9 is a sectional view of the third embodiment the conveyor idler roller shown in Figure 8.

DESCRIPTION OF EMBODIMENTS

[0027] Referring to Figures 2 to 9, the conveyor idler roller of the present invention is generally indicated by arrow 100. A roller head assembly 102 is positioned at each end of a cylindrical roller housing 104. Each roller head assembly 102 has an outer labyrinth seal 106 made of PTFE strip and a circular debris cover 108 made from steel plate. The outer labyrinth seal 106 interfaces with an inner labyrinth seal 110 to impede the ingress of dirt into a bearing which preferably a unit bearing 112.

[0028] The roller head assembly 102 has a stub axle 114 comprising a broach 116 which interfaces with a slot 24 in the conveyor idler frame support 26 (as shown in figure 1). In this way, the stub axle 114 and debris cover 108 are stationary when the roller head assembly 102 and the roller housing 104 are spinning. An outer seal 109 provides a barrier to the ingress of dirt between the debris cover 108 aperture and the protruding stub axle 114. The arrangement of the inner/outer labyrinth seal 110/106 and outer seal 109 can vary without departing from the scope of the present invention as shown in Figures 3 and 4.

[0029] An end cap 118 houses a stub axle 114 and a unit bearing 120 at each end of the roller housing 104. The stub axle 114 has a bearing seat 122 to retain the unit bearing 120 (shown in figures 6 and 7) against the end cap 118. The unit bearing 120 is retained in the end cap 118, by an internal circlip 124 (shown in figures 6 and 7). The stub axle 114 and unit bearing 120 is protected from the ingress of dirt internally within the roller housing 104 by a backing seal 126 or alternatively by an inner bearing seal or both.

[0030] Each stub axle 114 is connected via a connecting rod 128 wherein each end of the connecting rod passes through an aperture of each stub axle 114 and is retained in each stub axle 114 to fix the position of each stub axle 114 with respect to each other. In this way, improved ease of installation of the conveyor idler roller 100 in a conveyor idler support frame 26 is achieved via synchronization of the position of each broach 116 at each end of the connecting rod 128 to enable simultaneous insertion of each stub axle 114 in each respective slot 24 of the conveyor idler support frame 26. In addition, improved reliability of the conveyor idler roller 100 is achieved by keeping its rotation for longer even after wear to the roller housing 104 resulting decreased need for maintenance.

[0031] Each end of the connecting rod 128 is retained in each stub axle 114 by tack welding. However other retaining means could be used without departing from the scope of the present invention such as bolting or gluing. The connecting rod 128 is manufactured from light weight 8mm steel (such as 10 x 20 grade stainless steel) to not add any undue weight to the conveyor idler roller 100. Other light but rigid materials for the connecting rod 128 include carbon steel or vitreous steel.

[0032] In use, the conveyor idler roller 100 is manufactured by drilling an aperture in each pair of stub axles 114; extending the connecting rod 128 through the aperture in each of the stub axle 114 after passing the connecting rod 128 through a roller housing 104; and fixing each end of the connecting rod 128 to a respective stub axle 114 (by welding).

[0033] Thus preferred embodiments have a number of advantages over the prior art including:

• Improved ease of installation of conveyor idler rollers in a transport conveyor; and • Improved reliability of a conveyor idler roller and a resulting decreased need for maintenance.

[0034] In the present specification and claims (if any), the word 'comprising' and its derivatives including 'comprises' and 'comprise' include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0035] Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment' or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0036] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims (5)

1. A conveyor idler roller for a transport conveyor, the conveyor idler roller comprising:

Sa pair of end caps, each end cap pair member positioned at an opposite end of a conveyor idler roller housing for retaining a bearing pair member and a stub axle pair member at each end of the conveyor idler roller housing; and

Sa connecting rod

wherein each end of the connecting rod passes through an aperture of each stub axle pair member and is retained in each stub axle to fix the position of each stub axle pair member with respect to each other.

2. A conveyor idler roller for a transport conveyor as claimed in claim 1 wherein the connecting rod is manufactured from steel.

3. A conveyor idler roller for a transport conveyor as claimed in claim 1 or claim 2 wherein each end of the connecting rod is retained in each stub axle by welding.

4. A conveyor idler roller for a transport conveyor as claimed in any one of claims I to 3, wherein each stub axle pair member comprises a broach configured to be retained in a conveyor idler roller support frame to support each end of the conveyor idler roller.

5. A method of manufacture of a conveyor idler roller for a transport conveyor, wherein the method comprising the steps:

a. drilling an aperture in a pair of stub axles;

b. extending a connecting rod through a conveyor idler roller housing and the aperture in each of the stub axle pair members; and

c. retaining each end of the connecting rod in each of the stub axle pair members.