AU2022263548A1 - Equipment for replacement rollers in belt conveyors and a method for replacement rollers in belt conveyors - Google Patents

Abstract

This invention relates to equipment (1) for replacing rollers (2) in belt conveyors which comprises a trailer (3) configured to support a first articulated arm (4) to lift up the conveyor belt and a second articulated arm (5) for manipulation of the rollers (2) during the replacement ensuring efficiency, practicality, safety and ergonomics in this activity. This invention also refers to a method for replacement rollers (2), which makes use of the equipment (1) for replacing rollers (2), as mentioned above, significantly increasing the safety, ergonomics, efficiency and productivity of this maintenance activity 1/6 4 1 5 3 2 14 14 20 2 Figure 1

Description

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"EQUIPMENT FOR REPLACEMENT ROLLERS IN BELT CONVEYORS AND A METHOD FOR REPLACEMENT ROLLERS IN BELT CONVEYORS"

Field of Invention

[001] This invention relates to equipment to perform the replacement of carrying and

return rollers applied to belt conveyors, as well as a method for replacement rollers in

belt conveyors that makes use of the aforementioned equipment.

Background of the Invention

[002] Belt conveyors are mechanisms intended for the continuous transport of solid

bulk material or other types of products, using a belt as a means of traction and carrying

element of the material to be transported through it.

[003] The movement of the material occurs on a belt, generally continuous, with

reversible movement or not, which moves over pulley rollers and/or sliding tables,

horizontally or inclined, or even in curves, along a trajectory determined by the design

conditions, having characteristic parts or regions for loading and unloading of the

material.

[004] Such equipment basically consists of an endless belt, which is extended between

two drive pulleys (drive and return) and an internal structure built by laminated profiles,

carrying idlers (rollers supported on frames and return idlers (rollers supported on

frames) uxtaposed, on which the belt slides, allowing the handling of the material,

generally, ore.

[005] Due to the use of this equipment in a continuous demand regime, in direct contact

with abrasive materials and in adverse environmental conditions, it is necessary to

replace and maintain some components that make up the belt conveyor, including its

own carrying and return rollers.

[006] The replacement of carrying and return rollers in the belt conveyor is essential to

maintain the full operation of the equipment, since a damaged roller, whether carrying or

return, can significantly increase friction by contact with the belt and cause serious

accidents such as fire or belt tears.

[007] To replace the carrying rollers, it is necessary to carry out a kind of hoisting or

lifting of the belt, so that it loses contact with the carrying roller and allows the removal of

the rollers next to the idler frame and their respective replacement. Likewise, to replace

the return rollers, it is also necessary to lift and move the belt so that it loses contact with

the return roller and allows the replacement of the rollers.

[008] In the state of the art, this activity of replacing the rollers is performed manually

by employees with the aid of equipment or tools only to carry out the elevation or

removal of the belt in relation to the rollers to be maintained or replaced.

[009] The equipment commonly used in the state of the art includes lifting cranes, lifting

stands, standoffs and tools for manual lifting, all with the function of being in contact with

the belt close to the roller to be replaced and make a movement of this so that it loses

contact with the respective roller.

[010] The employee, with the help of one of the aforementioned equipment or tools,

moves the belt away from the roller to be replaced, allowing the employee to remove the

worn roller manually or with the help of tools often improvised, also carrying out the

installation of the new roller manually.

[011] In this way, the activity of replacing the rollers in the state of the art occurs with a

low level of safety and ergonomics, since the employee has to position himself in very

small spaces between the belt and the rollers of the belt conveyor to carry out this

manual replacement of the rollers, as well as the heavy weight of the roller that has to be

handled by employees during the activity.

[012] In addition, the roller replacement activity in the state of the art also presents low

efficiency and high runtime requiring the mobilization of at least three employees to

support the weight of a roller and position it, especially in the replacing of return rollers,

as well as high turnaround time for manual operations.

[013] There are, still in the state of the art, some patent documents that reveal

equipment applied to assist in the replace of belt conveyor rollers, such as, for example,

BR112013032790-4, which describes a system to perform the repair on a set of rollers.

Such a system, in a very brief way, comprises a lifting device, a robotic arm, a roller replacement device and, in alternative configurations, a base.

[014] The lifting device is configured to lift the belt and make it lose contact with the rollers to be replaced, consisting of a support structure that is lifted by means of hydraulic cylinders to be arranged in contact with the belt and lift it. When applied for the replace of return rollers, a different lifting device with specific constructive configuration is used.

[015] The robotic arm is configured to handle the elements and their positioning along the belt conveyor, including the positioning of the aforementioned lifting device. Such a robotic arm comprises a fixed base and a handle portion at its free end to enable association with the lifting device and the roller replacement device.

[016] The roller replacement device is configured to be in contact with the rollers to be replaced and to perform their manipulation by moving the robotic arm. Such a device comprises a free end to be coupled to the robotic arm and a retaining portion. Such a retaining portion comprises bars which are rotatable and which comprise a series of flaps configured to be arranged in contact with the roller to carry out the fixation with the device.

[017] In addition, one of the system configurations revealed in BR112014032790-4 comprises a base to support the robotic arm and other devices, the base being coupled to a vehicle to carry out the transport adjacent to the belt conveyor.

[018] However, although the document BR112014032790-4 reveals a system to assist in the repair and replacement of a belt conveyor roller set, it still has drawbacks and limitations regarding its application.

[019] The first inconvenience consists in the fact that the system of this document presents two types of lifting device and roller replacement device applied respectively to carrying rollers and return rollers, making it impossible to use a single device for both carrying and return rollers, reducing practicality and increasing activity time when it is necessary to replace both carrying and return rollers.

[020] The second inconvenience and limitation consist in the fact that both the lifting device and the roller replacement device are manipulated by the same robotic arm, making it necessary to first manipulate the lifting device, decouple the robotic arm, and dock on the roller replacement device, generating an increase in uptime by decoupling and coupling the same robotic arm.

[021] The third inconvenience and limitation lie in the access to certain belt conveyors

through vehicles only, since in some places it is impossible to access the belt conveyor

only by vehicles adjacent to the belt conveyor, especially with access through of trucks.

[022] The fourth inconvenience and limitation is the application of a robotic arm to

manipulate the devices, especially when applied to the activity of replacing return rollers,

which have a larger size and, consequently, heavier weight when compared to the

carrying rollers, so that a robotic arm is more likely to fail to support or perform such an

effort in this movement. In addition, the robotic arm suggested in document

BR112014032790-4 appears to be one of the most robust available on the market,

making the device with larger dimensions compared to a hydraulic system for the same

lifting/moving capacity, making it even more difficult to access areas with difficult access

and little space.

[023] In this way, at least for the inconveniences above, the system described in the

document BR112014032790-4 makes a practical and efficient replacement of both carrying rollers and return rollers impossible, as well as has limitations in its application.

[024] Another document, still in the state of the art, consists of BR112014023182-6

which reveals a device to lift a conveyor belt and perform the replacement of its roller

autonomously. Such an apparatus comprises a front carriage, a rear carriage, an

assembly for lifting the belt, loader arms, a mechanism for replacing rollers and roller

shelters.

[025] The movement of the device is carried out by the front carriage and by the rear

carriage on rails arranged on the side of the belt conveyor structure, so that it is able to

move above the belt conveyor. The assembly to lift the belt consists of two loader arms

configured to lift the belt and make it lose contact with the rollers to be replaced.

[026] The mechanism to replace rollers consists of a robotic arm equipped with

grippers at its end to pick up the rollers during replacement, both the worn rollers to be removed and the new rollers to be installed. Roller shelters are arranged on the carriages and configured to house new rollers to be installed and used rollers that have been removed from the belt conveyor, making it possible to reach them directly through the roller replacement mechanism.

[027] However, although document BR112014023182-6 also discloses an apparatus to assist in the operation of replacing belt conveyor rollers, it also has inconveniences and limitations regarding its application. The first limitation consists in the fact that the apparatus of the aforementioned document moves along tracks and above the belt conveyor, making it impossible or at least making it difficult to be applied in already implemented belt conveyors or in covered belt conveyors. Clearly, a specific design is required for each belt conveyor, with many specificities including belt width and deck width, making it impossible to apply a single device for exchanging rollers on more than one conveyor.

[028] Thus, at least for the above limitations, the document BR112014023182-6 does not allow a practical and efficient replacement of the carrying and return rollers on different belt conveyors using the same equipment, as well as its application in conveyors belt where there is no space above.

[029] It is concluded from the searches and analysis of the state of the art that there is no equipment for replacing rollers in belt conveyors that allows a practical and efficient replace of both carrying rollers and return rollers.

[030] In the state of the art, there is no equipment for exchanging rollers in belt conveyors that reveals a simple and unique constructive configuration for the replacement of both carrying rollers and return rollers.

[031] However, there is not, in the state of the art, equipment for replacing rollers in belt conveyors that allows its application in different belt conveyors, encompassing all possible belt widths according to ABNT NBR 6110:2015 and existing dimensions of rollers according to ABNT NBR 6678:2017, without access or space restrictions.

[032] Finally, in the state of the art, there is no method of replacing rollers in belt

conveyors that performs this activity with a high level of efficiency, productivity, safety

and ergonomics.

Objectives of the Invention

[033] This invention aims to provide equipment for replacing rollers on belt conveyors

that enables the practical and efficient replacement of both carrying rollers and return

rollers.

[034] This invention also aims to provide equipment for replacing rollers on belt

conveyors with a simple and unique configuration for the replacement of both carrying

rollers and return rollers.

[035] This invention also aims to provide equipment for replacing rollers on belt

conveyors that allows a wide application, encompassing all possible belt widths

according to ABNT NBR 6110:2015 and existing dimensions of rollers according to

ABNT NBR6678:2017.

[036] Finally, this invention also aims to provide a method of replacing rollers in belt

conveyors that features a high level of efficiency, productivity, safety and ergonomics.

Brief Description of Drawings

[037] This invention is illustrated in detail based on the respective figures:

[038] Figure 1 - reveals a perspective view of the equipment for replacing rollers on belt

conveyors of the present invention in its preferred configuration.

[039] Figure 2 - reveals a perspective view of the equipment trailer for replacing rollers

on belt conveyors of the present invention in its preferred configuration.

[040] Figure 3 - reveals a perspective view of the equipment trailer welded structure for

replacing rollers on belt conveyors of the present invention in its preferred configuration.

[041] Figure 4 - reveals a perspective view of the first base and second base of the

equipment trailer welded structure for replacing rollers on belt conveyors of the present

invention in its preferred configuration.

[042] Figure 5 - reveals a perspective view of the coupling of the equipment trailer welded structure for replacing rollers on belt conveyors of the present invention in its preferred configuration.

[043] Figure 6 - reveals a perspective view of the roller support of the trailer welded structure for replacing rollers on belt conveyors of the present invention in its preferred configuration.

[044] Figure 7 - reveals a bottom perspective view of the equipment trailer wheel bracket for replacing rollers on belt conveyors of the present invention in its preferred configuration.

[045] Figure 8 - reveals a perspective view of the lifting system of the equipment for replacing rollers on belt conveyors of the present invention in its preferred configuration.

[046] Figure 9 - reveals a perspective view of the first articulated arm of the equipment for replacing rollers on belt conveyors of the present invention in its preferred configuration.

[047] Figure 10 - reveals a perspective view of the second articulated arm of the equipment for replacing rollers on belt conveyors of the present invention in its preferred configuration. Summary of the Invention

[048] This invention, in its preferred configuration, discloses equipment for replacing rollers in belt conveyors that comprises: a trailer composed of a welded structure provided with an upper face and a lower face and a wheel support fixed to the bottom face of the welded structure; a first articulated arm attached to the upper face of the welded frame of the trailer for contacting a conveyor belt; and a second articulated arm fixed to the upper face of the trailer and arranged parallel to the first articulated arm to be arranged in contact and to carry out the manipulation of the rollers.

[049] The welded structure is composed of a rectangular-shaped rear portion and a triangular-shaped front portion, with the wheel support being fixed to the center of the rear portion of the welded structure and consisting of at least two wheels (7') and one suspension (7). Such a welded structure of the trailer comprises a first base for supporting the first articulated arm and a second base for supporting the second articulated arm, the first base and the second base being composed of longitudinal parallel beams and transverse parallel beams.

[050] The welded structure of the trailer also comprises coupling arranged at the end of the front portion to hook the trailer to vehicles, lifting eyes arranged at the ends of the rear portion to lift the trailer by means of lifting equipment and a support for rollers arranged parallel to the second base.

[051] The trailer comprises a lifting system composed of at least one pair of outriggers attached to the lower face of the rear portion of the welded structure to perform stabilization and change the height of the trailer. In its preferred configuration, the lifting system comprises two pairs of outriggers distributed on the underside of the rear portion of the welded structure so that the wheel support is arranged between two outriggers, the outriggers being equipped with a hydraulic cylinder in the horizontal direction to adjust its opening and a hydraulic cylinder in the vertical direction to adjust its height.

[052] The first articulated arm comprises a rotating base fixed to the first base by means of fixing screws, movement links with one end fixed to the rotating base and the other free end and a lifting device fixed to the free end of the movement links. Such a lifting device comprises coupling means to effect association with the free end of the movement links of the first articulated arm and an elongated flat plate linearly attached to the coupling means and configured to be arranged in contact with the surface of the conveyor belt. The coupling means are fixed to the free end of the movement links by means of fixing screws and the flat plate comprises rollers on its upper and lower face.

[053] The second articulated arm comprises a rotating base fixed to the second base by means of fixing screws, movement links with one end fixed to the rotating base and the other free end and a manipulation device fixed to the free end of the movement links. Such a manipulation device comprises an extender with one end fixed to the free end of the movement links of the second articulated arm by means of fixing screws and a claw attached to the opposite free end of the extender. The gripper of the manipulation device is configured to be arranged in contact with the central portion of the roller and comprises an opening and closing movement to couple and release the roller and a 180 movement to rotate the roller.

[054] The first articulated arm and the second articulated arm have a hydraulic drive

and movement, the first articulated arm, the second articulated arm and the lifting system

preferably controlled by means of a remote control manually activated by an employee.

[055] This invention, still in its preferred configuration, also reveals a method for

replacing rollers in belt conveyors, which makes use of the abovementioned equipment

for replacing rollers in belt conveyors, which comprises the following steps: positioning

the equipment to replace rollers with its trailer lateral to the belt conveyor; stabilizing and

adjusting the height of the equipment for replacing rollers by means of a lifting system

comprised by the trailer; lifting the conveyor belt by means of the first articulated arm;

removing the damaged roller from the belt conveyor by means of the second articulated arm and depositing the roller; installing a new roller on the belt conveyor by means of the

second articulated arm; retracting the second articulated arm into the trailer; and

retracting the first articulated arm into the trailer.

Detailed Description of the Invention

[056] Although this invention can be implemented in different modalities, its preferred

configurations appear in the figures and in the detailed description that follows, assuming

that the present description must be considered for merely illustrative purposes, not

limited to which is illustrated or described here.

[057] The main approach of the present invention reveals equipment 1 for replacing

rollers 2 applied to belt conveyors that allows replacement of both carrying rollers and

return rollers in a practical, efficient, safe and ergonomic way, without restrictions.

[058] In a preferred embodiment, equipment 1 for replacing rollers 2 comprises a trailer

3, a first articulated arm 4 and a second articulated arm 5, see Figure 1, each of its

components being described in detail below.

[059] Trailer 3 consists of the structure responsible for supporting and ensuring the

movement of all other components of equipment 1, allowing its positioning close to the belt conveyor. In its preferred configuration, said trailer 3 comprises a welded structure 6 and a wheel support 7, see Figure 2.

[060] Welded structure 6, as the name already suggests, consists of a structure formed

by beams and bars welded in order to form a kind of platform to support the other components of equipment 1 on its upper face and to couple with wheel support 7 on its

opposite face, i.e. on its underside.

[061] In its preferred configuration, welded structure 6 comprises a rear portion 6'

endowed with a rectangular shape and a front portion 6" endowed with a triangular

shape, being such an ideal format to allow the maneuver and movement of trailer 3 along passages adjacent to the belt conveyor.

[062] Still in its preferred configuration, welded structure 6 comprises a first base 8, a

second base 9, coupling 10, lifting eyes 11 and support for rollers 12, see Figure 3.

[063] The first base 8 and the second base 9 are configured to respectively receive the

first articulated arm 4 and the second articulated arm 5, allowing a secure fixation of

these components with welded structure 6. In their preferred configuration, the first base

8 and the second base 9 are arranged parallel to the center of the upper face of the 6'

rear portion of the welded structure 6.

[064] Still in its preferred configuration, the first base 8 and the second base 9 comprise

longitudinal parallel beams 8', 9' and transverse parallel beams 8", 9" welded to welded

structure 6. Longitudinal parallel beams 8', 9' are provided with plates with through holes for fixing the first and second articulated arms 4, 5 by means of fixing screws and nuts

passing through these holes, see Figure 4.

[065] In alternative configurations, the first base 8 and the second base 9 can have

different configurations than the longitudinal parallel beams 8', 9' and transverse parallel

beams 8", 9", varying according to the fixation of the base of the first and second articulated arm 4, 5 to be supported by the first and second bases 8, 9.

[066] The coupling 10 consists of the element configured to associate the trailer 3 with

a vehicle, allowing the movement of trailer 3 according to the movement of that vehicle.

Such coupling 10, in its preferred configuration, is arranged at the apex end of front portion 6" of welded structure 6, having a reinforced structure and a central hole to enable coupling with the vehicle.

[067 Still in its preferred configuration, to enable the movement of trailer 3 in different

types of terrains, the vehicle consists of a tractor or any other vehicle with high traction in

its wheels. In alternative configurations, the vehicle can be any self-propelled vehicle

other than tractors, such as trucks, vans, or others.

[068] To enable versatility and ease of coupling with different types of vehicles,

coupling 10, still in its preferred configuration, comprises a 10' height adjuster, making it

possible to raise or lower the height of the coupling 10 according to the movement height

adjuster 10', see Figure 5.

[069] In its preferred configuration, height adjuster 10' consists of a spindle actuated

manually by means of a crank, however, in alternative configurations, the height adjuster

' can consist of any other element capable of raising or lowering the 10 coupling, as

well as having an automatic activation by means of electric, hydraulic or pneumatic

energy.

[070] Lifting eyes 11, as its name suggests, consist of eyes configured to allow the

welded structure 6 and, consequently, equipment 1 of the present invention to be lifted

by means of lifting equipment. Such lifting eyes 11 and the respective movement of

trailer 3 through them are essential to enable equipment 1 to reach places inaccessible

by vehicles.

[071] In its preferred configuration, lifting eyes 11 are arranged close to each vertex of

rear portion 6'of welded structure 6, allowing the device to be lifted in a flat and balanced

way through these four lifting points to the positioning in places that are difficult to access

by vehicles.

[072] In alternative configurations, lifting eyes 11 can be arranged in other regions of

welded structure 6, being fundamental only that they are able to support and balance

equipment 1 of the present invention during its movement.

[073] In this way, through lifting eyes 11, equipment 1 can be hoisted by means of

lifting equipment such as cranes or others and positioned at the location where the

rollers are to be replaced

[074] Roller support 12, as its name suggests, consists of a structure configured to

house new rollers and damaged rollers taken from the belt conveyors. Such roller

support 12 is arranged on the upper face of rear portion 6' of the welded structure, close

to the second base 9, so that the second articulated arm 5 is able to reach roller support

12 and, consequently, deposit or withdraw rollers from this support.

[075] In its preferred configuration, roller support 12 is composed of two parallel

stringers 12' that allow a roller to be arranged in the space defined between parallel

stringers 12', preventing it from escaping roller support 12, see Figure 6.

[076] In alternative configurations, roller support 12 can reveal other constructive

configurations than parallel stringers 12', it being essential only that it is able to house

and support the rollers used and removed during the replacement made by equipment 1.

[077] Still in alternative configurations, trailer 3 may not comprise roller support 12, so

that the second articulated arm 5 deposits the roller removed from the belt conveyor on

the ground, as well as reaching new rollers also arranged on the ground next to

equipment 1.

[078] Still in relation to trailer 3 of equipment 1 of the present invention, its wheel

support 7 is described below, being configured to allow the movement of trailer 3 when it

is coupled with a vehicle through coupling 10. In its preferred configuration, wheel

support 7 is arranged just below the first base 8 and the second base 9, being the place

of greatest load of trailer 3, comprising wheels 7', suspension 7" and mudguards 13, see

Figure 7.

[079] Still in its preferred configuration, wheel support 7' comprises four wheels 7' with

tire for movement on different types of surface, mainly on uneven ground. To enable this

movement in places of difficult access, wheel support 7 also comprises a suspension 7"

which, in its preferred configuration, is of the tandem type with two axles, absorbing

impacts and preventing excessive movement of trailer 3 during its movement.

[080] Mudguard 13 is fixed around wheels 7' of the wheel support 7, preventing this material from being projected upwards when moving along muddy places and, consequently, to the other components of equipment 1 of this invention.

[081] In alternative configurations, wheel support 7 may comprise elements other than those mentioned in its preferred configuration above, for example, a set of tracks pulled on a driving wheel and guide wheels, commonly applied in tractors, facilitating the access in hard-to-reach areas.

[082] Due to the need to circulate and position trailer 3 of equipment 1 of this invention in rough terrain, as well as the application in different models and sizes of belt conveyors, trailer 3 comprises, still in its preferred configuration, system lift 14.

[083] Such a lifting system 14, in its preferred configuration, is attached to the lower face of rear portion 6' of welded structure 6, comprising at least a pair of hydraulically driven outriggers 14'. In its preferred configuration, lifting system 14 is composed of two pairs of hydraulically driven outriggers 14' arranged in parallel, so that wheel support 7 is arranged between outriggers 14'.

[084] Such 14' outriggers, in their preferred configuration, have an opening hydraulic cylinder on the horizontal axis to adjust the distance between 14' outriggers of the pair and a height hydraulic cylinder on the vertical axis to adjust the height of trailer 3 and perform the necessary leveling, see Figure 8.

[085] In alternative configurations, lifting system 14 can be composed of elements other than outriggers 14', as well as comprising a drive other than the hydraulic one, being fundamental only that the same guarantees stability of trailer 3 close to the ground and the possibility of varying its height to suit different belt conveyors.

[086] Thus, having described trailer 3 of equipment 1 of the present invention and its main components, the first articulated arm 4 and the second articulated arm 5 are described in detail below.

[087] The first articulated arm 4, as mentioned above, is fixed to the first base 8 of welded structure 6 of trailer 3, being the same configured to carry out an elevation of the belt and make it lose contact with the roller 2 that if you wish to replace by means of equipment 1 of the present invention.

[088] In its preferred configuration, the first articulated arm 4 comprises a rotating base 4' that is fixed to the first base 8 by means of fixing screws, movement links 4" that allow the movement of the first articulated arm 4 and a lifting device 15 fixed to the free end of the movement links 4", see Figure 9.

[089] Still in its preferred configuration, all movement of the first articulated arm 4, from its rotating base 4' to the free end of the movement links 4", is carried out by means of hydraulic energy, with the application of hydraulic cylinders on its 4' rotating base and 4" movement links to position the first articulated arm 4, supporting high loads for lifting the belt.

[090] In alternative configurations, the first articulated arm 4 can be composed of components other than the rotating base 4' and the movement links 4", as well as having another drive source other than hydraulics, such as a robotic or pneumatic arm.

[091] Lifting device 15 consists of the element that is fixed next to the free end of the first articulated arm 4 and configured to be arranged in contact with the surface of the belt, causing it to be lifted and lose contact with roller 2. In its preferred configuration, lifting device 15 comprises coupling means 15'and flat plate 15", see Figure 9.

[092] Coupling means 15', as its name suggests, consists of the component responsible for associating the free end of the movement links 4" of the first articulated arm 4 with lifting device 15, being in its preferred configuration fixing screws and nuts are applied. In alternative configurations, coupling means 15' may consist of snaps or other quick coupling means other than fastening screws and nuts.

[093] Flat plate 15" consists of the element of lifting device 15 responsible for being in direct contact with the belt, consisting of an elongated plate with a flat upper face and a lower face. In its preferred configuration, 15" flat plate comprises rollers arranged along its upper and lower faces to reduce friction generated by contact with the belt.

[094] Due to the constructive configuration of lifting device 15 and its flat plate 15", it can be used to be in contact with both the belt in its carrying region and in its return region, making it possible to perform the removal of the belt for the replacement of carrying and return rollers by means of this same equipment, without having to stop the activity to replace lifting device 15 or any of its components.

[095] In this way, by means of the movement of the first articulated arm 4, the lifting device 15 is arranged in direct contact with the belt of the belt conveyor, positioning its flat plate 15" below the belt and carrying out its elevation by means of the movement of the articulated arm 4, causing the belt to lose contact with the roller 2 and the second articulated arm 5 to be able to perform the replacement, as described below.

[096] The second articulated arm 5, as mentioned above, is fixed to the second base 9 of welded structure 6 of trailer 3, being the same configured to perform the manipulation of roller 2 that you want to remove from the belt conveyor and the new roller that you want to install.

[097] In its preferred configuration, the second articulated arm 5 comprises a rotating base fixed to the second base 9 by means of fixing screws, movement links 5" to carry out the positioning of the second articulated arm 5 and a manipulation device 16 to handle rollers 2, see Figure 10.

[098] Still in its preferred configuration, all movement of the second articulated arm 5, from its rotating base 5' to the free end of its movement links 5", is carried out by means of hydraulic energy, with the application of hydraulic cylinders on its 5' rotating base and movement links 5" to position the second articulated arm 5, supporting high loads for manipulation rollers 2.

[099] In alternative configurations, the second articulated arm 5 can be composed of components other than the rotating base 5' and the movement links 5", as well as having another drive source other than hydraulics, such as a robotic or pneumatic arm.

[0100] Manipulation device 16 is fixed to the free end of the movement links 5" of the second articulated arm 5, being the same configured to carry out the association of the second articulated arm 5 with rollers 2 and allow its movement during the replacement. Such manipulation device 16, in its preferred configuration, comprises an extender 16' and a gripper 16", see Figure 10.

[0101] Extender 16'consists of an elongated beam with one end fixed to the free end of the movement links 5'of the second articulated arm 5 by means of fixing screws and the other end fixed to gripper 16" by means of a rotary joint. Such extender 16' is configured to allow gripper 16" to reach all rollers 2 of the same cross section (idler) of the belt conveyor, including rollers 2 arranged on the opposite sides of equipment 1 of the present invention, ensuring the necessary extension for manipulation device 16. This configuration reduces uptime as it eliminates the need to move equipment 1 to the other side of the belt conveyor to replace the opposite roller.

[0102] Gripper 16" is configured to carry out the association of roller 2 with manipulation

device 16, having an opening and closing movement to grip and release rollers 2. In its

preferred configuration, gripper 16" comprises an opening and closing drive by means of

a hydraulic cylinder, ensuring the necessary force to prevent roller 2 from coming loose

during its manipulation.

[0103] Still in its preferred configuration, gripper 16" comprises a 1800 movement in its

rotating joint with the extender 16' to allow it to have better access to the rollers 2 to be

replaced and, mainly, that it be able to rotate rollers 2 to complete the installation.

[0104] By means of the 16" gripper, it is possible to carry out the association with both

carrying rollers and return rollers, so that its hydraulic drive and the hydraulic drive of the

second robotic arm 5 are robust enough to withstand the necessary effort, including for

the handling of return rollers, avoiding the need to exchange the handling device 16 for

the replacement of return rollers.

[0105] In an alternative configuration, extender 16' of handling device 16 can be used to

remove the return roller without using claw 16", so that straps 20 are used to assist in the

removal of the return roller, as illustrated in Figure 1. It should be noted that this

alternative configuration only applies to the removal of the return roller, which has to be

installed through 16" gripper due to the rotary movement necessary for the effective

installation of the new return roller.

[0106] However, it is important to note that this alternative configuration still allows the

use of two articulated arms simultaneously (the first articulated arm 4 lifting the belt and

the second articulated arm 5 manipulating roller 2), without any type of loss for exchanging grippers or making adjustments.

[0107] Still in alternative configurations, 16" gripper may have another opening and

closing drive other than the hydraulic cylinder, such as an electric motor or pneumatic

cylinder, as well as not having this 1800 movement to enable access and rotate rollers 2.

[0108] In this way, while the first articulated arm 4 is positioned carrying out the lifting of

the belt by means of the lifting device 15, the second articulated arm 5 carries out the

movement of the manipulation device 16 to remove the worn roller 2 and install a new

roller 2, completing the replacement of roller 2.

[0109] Equipment 1 for replacing rollers 2 of the present invention, in its preferred

configuration, as mentioned above, is driven by hydraulic energy, with hydraulic cylinders

being applied in the vast majority to carry out the movement and actuation of the first

articulated arm 4, the second articulated arm 5 and lifting system 14. In alternative

configurations, other means of actuation can be used, such as electric motors or

pneumatic drives.

[0110] Still in its preferred configuration, all this control of equipment 1 of the present

invention is carried out through a remote control manually controlled by an employee

close to the belt conveyor, allowing him or her to have a broad view and be able to control all movements needed during the replacement activity for roller 2. Equipment 1 of

the present invention can also comprise cameras and lighting systems to facilitate and

assist in the visualization by the employee during the replacement activity for roller 2

through equipment 1.

[0111] Equipment 1 of the present invention can also comprise presence sensors in the

action radius of the articulated arms 4, 5 to avoid the presence of people in areas of risk

of collision with the moving parts to guarantee the safety of the employee during the

replacement activity for roller 2 through equipment 1.

[0112] In alternative configurations, the control of equipment 1 can be carried out

automatically by installing sensors on the first articulated arm 4 and on the second

articulated arm 5, so that equipment 1 is able to replace rollers 1 autonomously or semi

autonomously.

[0113] Having described equipment 1 for replacing rollers 2 on belt conveyors of the present invention, the method for replacement rollers 2 on belt conveyors using equipment 1, which is composed of seven steps described in detail below.

[0114] The first step consists of positioning equipment 1 laterally to the belt conveyor, more specifically positioning its trailer 3 so that the first articulated arm 4 and the second articulated arm 5 can reach roller 2 that you wish to replace.

[0115] This positioning, as already mentioned, can be performed either by coupling trailer 3 of equipment 1 with a vehicle through coupling 10 or by lifting trailer 3 on a lifting machine, such as a crane, through lifting eyes 11.

[0116] In the first alternative, equipment 1 is coupled to a vehicle and moved in a passage adjacent to the belt conveyor to the place where maintenance is desired, performing the positioning of equipment 1 by land.

[0117] In the second alternative, equipment 1 is hoisted by means of a lifting machine such as a crane and then positioned next to the belt conveyor, performing the positioning of equipment 1 by air, especially when access by land route is not possible.

[0118] With equipment 1 positioned close to the belt conveyor, the second stage begins, which consists of stabilizing equipment 1 and adjusting its height, especially when applied on rough terrain or on high-height belt conveyors.

[0119] In this second stage, this stabilization and height adjustment of equipment 1 is carried out through its lifting system 14, causing it to be activated and its outriggers 14' to be expanded and come into contact with the ground, ensuring the stability and height necessary for the respective movements of equipment 1.

[0120] The third stage begins when equipment 1 is already stabilized and at an adequate height, making it possible to lift the belt of the belt conveyor through the first articulated arm 4. In this step, the first articulated arm 4 is manipulated so that the lifting device 15 is in contact with the belt and lifts it, causing the belt to lose contact with roller 2 to be replaced.

[0121] Due to the constructive configurations of lifting device 15, it can be used both to perform the removal of the belt in its carrying region, when replacing carrying rollers, and in its return region when replacing return rollers, being this third step, as well as the others, applicable for both maintenances.

[0122] With the belt still elevated and without contact with roller 2, the fourth stage

begins, which consists of removing the damaged roller 2 from the belt conveyor through

the second articulated arm 5. In this step, the second articulated arm 5 is manipulated so

that its manipulation device 16 comes into contact with roller 2 and carries out its

removal.

[0123] More specifically, in this fourth step, gripper 16" of handling device 16 is coupled

to the central portion of roller 2, whether it is a carrying or return roller, through its closing

movement, ensuring that it is securely associated with manipulation device 16 to carry

out the respective removal manipulations.

[0124] Still in this fourth stage, the damaged roller 2 and removed from the belt

conveyor is handled by the second articulated arm 5 and deposited on the floor or on

roller support 12, so that it can be transported together with equipment 1 and brought to

the workshop or place to verify the possibility of maintenance or reuse. In order to

deposit the roller on roller support 12, the gripper 16" of handling device 16 performs its

opening movement, causing the roller 2 to detach from the handling device 16.

[0125] With the damaged roller 2 removed and deposited on roller support 12 or on the

floor itself, the fifth stage begins, which consists of installing a new roller 2 on the belt

conveyor also through the second articulated arm 5. In this step, the second articulated

arm 5 couples a new roller 2 arranged on the roller support 12 or previously positioned

on the floor itself next to equipment 1 and moves the roller to the belt conveyor's stand

where the installation is to be carried out.

[0126] This coupling of the new roller 2 with the second articulated arm 5 is also carried

out through the manipulation device 16, more specifically through its gripper 16" which

performs a closing movement in the central region of roller 2, ensuring a secure

association between these elements during manipulation.

[0127] In order to install the new roller 2, the second articulated arm 5 also makes use

of its handling device 16, more specifically positioning the new roller 2, removed from roller support 12, on the belt conveyor stand and performing a rotating movement through gripper 16", allowing a proper installation of the same.

[0128] Upon completion of the installation of the new roller 2 on the belt conveyor in the fifth stage, the sixth stage consists of moving and collecting the second articulated arm , returning its handling device 15 to trailer 3 of equipment 1, removing it under the conveyor belt.

[0129] In this step, handling device 16 of the second articulated arm 5 performs an opening movement of its gripper 16", leaving the new roller 2 installed on the belt conveyor and allowing its respective free movement into trailer 3.

[0130] With the second articulated arm 5 retracted, the seventh and final stage begins, which consists of moving and retracting the first articulated arm 4, so that its lifting device is moved so that the belt returns to contact with the new roller 2 installed and respectively removed from the contact with the belt, completing the replacement of roller 2. With the belt in contact with roller 2, the lifting device 15 is retracted into trailer 3 by moving the first articulated arm 4.

[0131] In this way, with the first articulated arm 4 and the second articulated arm 5 collected in trailer 3 of equipment 1 of the present invention, it can proceed to a next point where it is necessary to replace rollers 2 on the same or another belt conveyor or return to the workshop.

[0132] It should be noted that, as mentioned above, all movements of equipment 1 in the steps of the roller replacement method 2 of the present invention, with the exception of the first step, in its preferred configuration, are carried out by means of a remote control operated manually by an employee. In alternative configurations, such movements can be performed autonomously or semi-autonomously.

[0133] Having described both equipment 1 for replacing rollers 2 on belt conveyors, and the method of replacing rollers 2 on belt conveyors, it is clear that the present invention brings significant advantages over the state of the art and fulfills with the proposed objectives.

[0134] Such advantages consist of increased safety and ergonomics during the replacement of rollers 2 of belt conveyors, not requiring any type of physical effort or position with low ergonomics on the part of the employees involved in the operation, since all movements of rollers 2 that are being exchanged are carried out by a first articulated arm 4 and by a second articulated arm 5, without the need for direct contact between the employee and rollers 2.

[0135] The increase in safety and ergonomics is also achieved by the lack of need for assembly and disassembly of devices or equipment to carry out the lifting of the belt so that it loses contact with roller 2 that is to be replaced, performing this elevation of the belt through the first articulated arm 4 and its lifting device 15, without the need for direct contact between the employee and the belt or other components.

[0136] Another advantage of the present invention is the increase in efficiency and productivity in the activity of replacement rollers 2 of belt conveyors, substantially reducing the time required to perform this operation, especially when it is necessary to replace both carrying rollers and return rollers at the same location.

[0137] This is because, by means of the equipment 1 for replacing rollers 2 of the present invention, it is possible to lift the belt and manipulate roller 2, whether carrying or return roller, respectively through the first articulated arm 4 and second articulated arm 5, without the need for other equipment or devices or exchange of accessories or devices of equipment 1 itself.

[0138] In addition, the present invention also brings gains in relation to the accessibility and application of equipment 1 for replacing rollers 2 in different types and sizes of belt conveyors, allowing equipment 1 to be moved both by land through coupling 10 to a vehicle, or by the air through lifting eyes 11 on lifting equipment such as cranes, allowing access of equipment 1 in areas of difficult access.

[0139] Therefore, the present invention mitigates the problems inherent in this activity in the state of the art, in addition to promoting improvements in safety and ergonomics and increasing efficiency and productivity, as explained above, constituting a new and effective piece of equipment.

[0140] Thus, although only few modalities of this invention have been shown, it will be understood that various omissions, substitutions, and alterations may be made by a skilled person without departing from the spirit and scope of the present invention. The modalities described shall be considered in all respects only as illustrative and not restrictive.

[0141] It is expressly provided that all combinations of elements that perform the same function in substantially the same way to achieve the same results are within the scope of the present invention. Substitutions of elements from one described modality to another are also fully intended and contemplated.

[0142] It should be noted that the drawings are not necessarily to scale, having a purely conceptual nature. The intent of the invention proposed by the present application may therefore be limited, as indicated by the scope of the appended claims.

Claims (20)

1. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

characterized by the fact that comprises: a trailer (3) composed of a welded structure

(6) provided with an upper face and a lower face and a wheel support (7) fixed to the bottom face of the welded structure (6); a first articulated arm (4) attached to the upper

face of the welded structure (6) of the trailer (3) for contacting a conveyor belt; and a

second articulated arm (5) fixed to the upper face of the welded structure (6) of the trailer

(3) and arranged parallel to the first articulated arm (4) to be arranged in contact and to

carry out the manipulation of the rollers (2).

2. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 1, characterized by the fact that the welded structure (6) is

composed of a rectangular-shaped rear portion (6') and a triangular-shaped front portion (6"), with the wheel support (7) being fixed to the center of the rear portion (6") of the

welded structure (6) and consisting of at least two wheels (7') and one suspension (7).

3. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 2, characterized by the fact that the welded structure (6) of the trailer

(3) comprises a first base (8) for supporting the first articulated arm (4) and a second base (9) for supporting the second articulated arm (5), the first base (8) and the second

base (9) being composed of longitudinal parallel beams and transverse parallel beams.

4. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 2, characterized by the fact that the welded structure (6) of the trailer

(3) comprises coupling (10) provided at the end of the front portion (6") for coupling the

trailer (3) in vehicles.

5. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 2, characterized by the fact that the welded structure (6) of the trailer

(3) comprises lifting eyes (11) provided at the ends of the rear portion (6) for lifting the

trailer (3) through lifting equipment.

6. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 2, characterized by the fact that the trailer (3) comprises a lifting system (14) composed of at least one pair of outriggers (14') fixed to the lower face of the rear portion (6') of the welded structure (6) to stabilize and change the height of the trailer (3).

7. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS, according to claim 6, characterized by the fact that the lifting system (14) comprises two

pairs of outriggers (14') distributed on the underside of the rear portion (6') of the welded

structure (6) so that the wheel support (7) is arranged between two outriggers (14'), the

outriggers (14') being equipped with a hydraulic cylinder in the horizontal direction to

adjust its opening and a hydraulic cylinder in the vertical direction to adjust its height.

8. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 3, characterized by the fact that the welded structure (6) comprises a

roller support (12) parallel to the second base (9).

9. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 3, characterized by the fact that the first articulated arm (4)

comprises a rotating base (4') fixed to the first base (8) by means of fixing screws,

movement links (4") with one end fixed to the rotating base (4') and the other free end

and a lifting device (15) fixed to the free end of the movement links (4").

10. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 9, characterized by the fact that the such a lifting device (15)

comprises coupling means (15') to effect association with the free end of the movement links (4") of the first articulated arm (4) and an elongated flat plate (15") linearly attached

to the coupling means (15') and configured to be arranged in contact with the surface of

the conveyor belt.

11. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 10, characterized by the fact that the coupling means (15') are fixed to the free end of the movement links (4") by means of fixing screws and the flat plate

(15") comprises rollers on its upper and lower face.

12. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claim 3, characterized by the fact that the second articulated arm (5) comprises a rotating base (5') fixed to the second base (9) by means of fixing screws, movement links (5") with one end fixed to the rotating base (5') and the other free end and a manipulation device (16) fixed to the free end of the movement links (5").

13. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS, according to claim 12, characterized by the fact that the manipulation device (16)

comprises an extender (16') with an end fixed to the free end of the movement links (5')

of the second articulated arm (5) by means of fixing screws and a gripper (16") fixed to

the extender's (16') free opposed end.

14. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS, according to claim 13, characterized by the fact that the gripper (16") of the

manipulation device (16) is configured to be arranged in contact with the central portion

of the roller (2) and comprises an opening and closing movement to couple and release the roller (2) and a 180 movement to rotate the roller (2).

15. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS,

according to claims 9 and 12, characterized by the fact that the first articulated arm (4)

and the second articulated arm (5) have hydraulic drive and movement.

16. EQUIPMENT (1) FOR REPLACING ROLLERS (2) IN BELT CONVEYORS, according to claim 6, characterized by the fact that the first articulated arm (4) and the

second articulated arm (5) and the lifting system (14) are controlled through a remote

control manually activated by an employee.

17. METHOD FOR REPLACING ROLLERS (2) IN BELT CONVEYORS, which

makes use of the equipment (1) for replacing rollers (2) in belt conveyors as defined in

claim 1, characterized by the fact that it comprises the following steps:

i. Position the equipment (1) for replacing rollers (2) with its trailer (3) close to the belt

conveyor; ii. Stabilize and adjust the height of the equipment (1) for replacing rollers (2) by means

of a lifting system (14) comprising the trailer (3);

iii. Lift the conveyor belt by means of the first articulated arm (4);

iv. Remove the damaged roller (2) from the belt conveyor by means of the second articulated arm (5) and deposit the roller (2); v. Install a new roller (2) on the belt conveyor through the second articulated arm (5); vi. Retract the second articulated arm (5) into the trailer (3); vii. Retract the first articulated arm (4) into the trailer (3).

18. METHOD FOR REPLACING ROLLERS (2) IN BELT CONVEYORS, according to claim 17, characterized by the fact that the positioning of step i is carried out by means of a vehicle that couples and moves the trailer (3) of the equipment (1)) for replacing rollers (2).

19. METHOD FOR REPLACING ROLLERS (2) IN BELT CONVEYORS, according to claim 17, characterized by the fact that the positioning of step i is carried out by means

of a piece of lifting equipment that lifts up the trailer (3) of the equipment (1)) for

replacing rollers (2).

20. METHOD FOR REPLACING ROLLERS (2) IN BELT CONVEYORS, according to

claim 17, characterized by the fact that the movements of stages ii, iii, iv, v and vii are

controlled through a remote control manually activated by an employee.

Figure 1

Figure 3 Figure 2

Figure 5 Figure 4

Figure 7 Figure 6

32

Figure 9 Figure 8

Figure 10