JPH09263314A - Manufacture of tapered roller for curved conveyor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To greatly simplify a manufacturing process by bending raw material cut in a fan shape and by welding the butted portions thereof to thereby make a tapered roller body. SOLUTION: A thin steel plate is cut in a fan shape to make two sheets of first raw material 11a, 11a. The size of the first raw material 11a, 11a is set at the size required to obtain a taper or an inner diameter of small diameter side and an outer diameter of large diameter side of a roller body 11. (A). Two sheets of first raw material 11a, 11a are bent in a semi-circular shape by using a press, respectively. In this step, the small diameter side and the large diameter side are bent in a semi-circular shape. (B). The secondary raw materials 11b, 11b are butted and the butted portions 11c, 11c are welded by a laser. (C). Since the butted portions 11c, 11c are welded by a laser, extremely few beads are produced because of the characteristic of a laser welding and, hence, after-working such as polishing or the like is not required.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a taper roller used in a curve conveyor.

[0002]

2. Description of the Related Art A curved conveyor 1 used in the swivel part of a conveyor line has a smaller radius R as shown in FIG.
By turning the luggage W compactly, the installation space can be saved only in the range shown by S in the figure, but in recent years it has been possible to provide such a compact curved conveyor from the viewpoint of effectively utilizing the space in the factory. Is desired.

On the other hand, since the curve conveyor 1 conveys the cargo W while smoothly rotating it without deviating from the conveyance direction, it is necessary to increase the conveyance speed on the outside of the revolution rather than on the inside of the revolution. As shown in FIG. 5, taper rollers 2 to 2 having a small diameter on the inside of the turning and a large diameter on the outside of the turning are used for the above. Therefore, in order to rotate the load with a smaller radius R, it is necessary to make a large difference between the transport speed on the inside of the swing and the transport speed on the outside of the swing, and as a result, the taper degree T of the taper roller 2 is increased. There is a need to. That is, the taper degree T of the taper roller 2 is given by T = di / R, where di is the outer diameter on the small diameter side (inward of turning) as shown in the figure, and the outer diameter di on the small diameter side is Shape of luggage,
The taper degree T is inevitably increased if the turning radius R is reduced, because the size or weight is determined.

[0004]

As described above, in order to obtain a more compact curve conveyor 1, it is necessary to make the taper degree T of the taper roller 2 larger, but the conventional taper roller 2 is Since the outer diameter of the pipe material as a raw material was manufactured by swaging to draw until the desired taper degree T was obtained,
There were the following problems.

First, although the outer diameter dimension can be accurately machined by swaging, since the pipe material at the material stage has a relatively large variation in plate thickness, the inner diameter dimension must be made uniform. Was extremely difficult. Here, as shown in FIG. 7, on both inner diameter sides of the tapered roller 2,
Bearings 3 and 3 are mounted via bearing housings 4 and 5 to rotatably support the tapered roller 2 with respect to the shaft 6. Therefore, if the inner diameters di and Di (see FIG. 8) at both ends are small, the bearing housings 4 and 5 cannot be inserted. On the contrary, if the inner diameters di and Di are large, both ends are caulked as shown in FIG. However, there is a problem that the bearing housings 4, 5 and thus the bearings 3, 3 cannot be firmly fixed.

Therefore, conventionally, after swaging,
The inner diameter side of both ends of the taper roller 2 is post-processed as shown in FIG. 8 (lathe lathe processing on the inner circumference, the portion expanded in the radial direction in the figure).
However, since the method of making the inner diameter dimensions di and Di constant by this is adopted, it takes time and labor to manufacture the taper roller 2.

Secondly, if the taper degree T of the taper roller 2 is increased in order to save the installation space as described above, a large swaging machine having a larger processing force is required, resulting in cost reduction. There was a problem of inviting up.

Thirdly, during swaging, the pipe material as a raw material is required to have a certain strength or more in order to avoid buckling and dents. Therefore, inexpensive SGP (carbon steel pipe for piping) and plate thickness are required. Thin pipe material (t1,6, t1)
However, there is a problem in that STKM (carbon steel pipe for machine structure), which is more expensive than these materials, cannot be used as a raw material, and the material must be used as a raw material.

Fourth, the swaging process requires a mold capable of withstanding a large processing force, which causes a problem of increasing the initial cost.

It is an object of the present invention to provide a method of manufacturing a taper roller for a curved conveyor which can solve the above conventional problems.

[0011]

Therefore, the manufacturing method according to the first aspect is characterized in that the material cut into a fan shape is bent and the abutting portions thereof are joined to manufacture the tapered roller body.

According to this manufacturing method, the tapered roller body is manufactured by bending a flat plate as a material. Since the flat plate as a material does not have the plate thickness variation as much as the pipe material and is bent, the inner and outer diameters of the taper roller body can be made uniform with a higher accuracy than ever before, and therefore the conventional Since the bearing can be firmly held without post-processing on both inner diameter sides, the manufacturing process can be greatly simplified, and the first problem can be solved.

In this case, if the joining of the abutting portions after the bending process is performed by laser welding or TIG welding, the welding can be performed with almost no welding beads, so that the joining portions can be joined without any post-treatment. It can be finished neatly and can further contribute to process simplification and cost reduction.

Since the taper roller is manufactured by bending, it is possible to easily manufacture a taper roller having a large taper degree by properly setting the fan shape at the material stage and the press die for bending. Also, even with a large taper degree, unlike the conventional swaging process, since it can be manufactured with the same processing force (bending force), there is no increase in equipment cost, which causes the second problem. Will be resolved.

Next, since the taper roller is manufactured by bending, it is not necessary to consider the strength as a raw material as in the case of the conventional swaging, and therefore a thin plate (t1.6, t1) which is inexpensive as a raw material is used. Etc. can be utilized, the cost of the material can be reduced, and the third problem can be solved by this.

Further, since a large processing force is not required as in the case of the conventional swaging, it is possible to reduce the cost of the press die for bending, which solves the fourth problem. .

The manufacturing method according to claim 2 is the method for manufacturing a taper roller according to claim 1, wherein at least the peripheral surface of the taper roller main body on the large diameter side is subjected to half punching, and the half punching portion is used. A disk-shaped holding plate is mounted on the inner peripheral side of the taper roller by positioning in the axial direction, and a bearing is mounted on at least the large diameter side of the taper roller via the holding plate.

According to this manufacturing method, the diameter of the holding plate is manufactured so as to match the maximum diameter of the taper roller, so that the circumference of the holding plate can be adjusted as it is or in accordance with the inner diameter of the taper roller on the large diameter side. For example, by cutting by laser cutting (cutting into a smaller diameter), 1
Various kinds of holding plates can be used for the taper rollers of various sizes, and in this respect, the manufacturing cost of the holding plate can be reduced.

Here, if the inner and outer diameters of the taper roller on the small diameter side and the taper degree are the same, the inner diameter dimension and the outer diameter dimension on the large diameter side vary depending on the roller width L (length). On the other hand, conventionally, the bearing housing for mounting the bearing at the end of the taper roller is formed in a substantially cylindrical body, and its diameter is a dedicated product that matches the inner diameter of the large diameter side of the taper roller. It could not be diverted to a taper roller with a small diameter. For this reason, conventionally, it is necessary to prepare a bearing housing on the large diameter side according to the type of roller width to be set, which increases the number of parts, resulting in an increase in part management or part manufacturing costs. there were. In this respect, according to the invention of claim 2, since the holding plate is not a cylindrical body but a disc shape, one kind of holding plate is manufactured according to the maximum diameter of the taper roller, and this is used as it is. Alternatively, it can be cut into a smaller diameter as appropriate according to the inner diameter on the larger diameter side. As described above, since only one type of holding plate is required, the number of parts can be reduced and the management thereof can be simplified as compared with the conventional one, and the manufacturing cost of a press die or the like for manufacturing the holding plate can be reduced.

According to a third aspect of the present invention, there is provided a tapered roller production method according to the second aspect, wherein a bearing housing for holding a bearing on the small diameter side is attached to a holding plate,
The bearing housing is commonly used on the large diameter side and the small diameter side.

According to this manufacturing method, the bearing on the small diameter side is mounted on the holding plate because the bearing on the large diameter side is mounted on the holding plate via the bearing housing for the small diameter side instead of directly mounting the bearing on the holding plate. Can also be used for the large diameter side, and in this respect, it is possible to reduce the number of parts or the manufacturing cost thereof.

[0022]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment of the present invention will be described with reference to FIGS.
It will be described with reference to FIG. FIG. 1 shows a procedure for manufacturing the roller body 11 of the tapered roller 10 according to this embodiment. First, as shown in FIG. 1 (A), a thin steel plate (for example, t1.0) is cut into a fan shape to prepare two primary materials 11a and 11a.

The dimensions of the respective parts of the primary materials 11a, 11a are such that the taper degree T of the roller body 11 finally required, the inner and outer diameters di, do on the small diameter side and the inner and outer diameter D on the large diameter side.
The dimensions are set to obtain i and Do.

Next, as shown in FIG. 1B, the two primary materials 11a and 11a are bent into semicircular shapes using a press die. At this stage, the small-diameter side and the large-diameter side are bent into semicircles. The secondary materials 11b and 11b thus obtained are butted as shown in FIG. 1 (C), and the butted parts 11c and 11c are laser-welded.

By the above procedure, the tapered roller body 11 is obtained. Since the abutting portions 11c, 11c of the roller body 11 are joined by laser welding, the welding bead is extremely small in view of their characteristics, and therefore they can be used in the subsequent steps without post-processing such as polishing.

Next, the large diameter side of the roller body 11 is subjected to so-called half punching as shown in FIG. This half blanking is used as a positioning means for axially positioning the bearing mounted on the large diameter side.
This half punching process is performed by making a plurality of cuts at appropriate positions in the circumferential direction on the large diameter side (shown at 6 positions in the figure) and a part of the wall thickness at the same position in the axial direction with a suitable width. It is formed by projecting inward in the plate thickness direction, and a processing method that has been generally used in the past has been used. According to this processing method, since the half punched portions 11d to 11d are formed by projecting inward with a part of the wall thickness being smaller than the plate thickness (t1.0), the inner and outer portions are formed. No gap is generated between them, and therefore foreign matter does not enter the inside of the roller body 11.

Further, since the abutting end surfaces 11e to 11e of the half punched portions 11d to 11d are formed as flat surfaces aligned on the same surface 11f orthogonal to the axis, the holding plate 12 will be described in the axial direction. Is reliably positioned. In this respect, as the axial positioning means of the holding plate 12, for example, a protrusion protruding inward may be formed at an appropriate position in the circumferential direction, instead of the illustrated half punching process. Since the contact with 12 is a line contact, half punching is more preferable from the viewpoint of surely positioning in the axial direction. However, as long as the positioning of the holding plate 12 is surely performed, the positioning is not limited to the half punching process, and other positioning means such as the above-mentioned protrusion may be used.

Next, the holding plate 12 is formed by punching into a substantially disc shape as shown in FIG. 3, and is provided with a flange portion 12a and a boss portion 12b. Radial projections 12c to 1 are provided at six locations in the circumferential direction of the flange portion 12a.
Since 2c is formed by bending, sufficient rigidity is secured in the flange portion 12a.

The boss portion 12b is formed at the center of the flange portion 12a and on the protruding side of the convex portions 12c to 12c. The inner diameter of the boss portion 12b is set to a diameter into which the bearing housing 13 on the smaller diameter side can be fitted.

The bearing housing 13 on the small diameter side has a substantially disc shape, and is provided with a recess 13a at the center thereof for mounting the bearing 14 in a fitting shape. The bearing housing 13 on the small diameter side is used for both the small diameter side and the large diameter side of the taper roller 10. That is, as shown in FIG. 4, the bearing 14 is mounted by directly fitting the bearing housing 13 on the small diameter side and the bearing housing 1 on the large diameter side.
The bearing 14 is mounted by fitting the holding plate 12 in which 3 is fitted into the boss portion 12b.

The holding plate 12 has the convex portions 12c to 12c directed inward as shown in FIG.
The flat portion in which the convex portion 12c of "a" is not formed is fitted into the abutting end surfaces 11e to 11e of the half punched portion 11d. Thereby, the holding plate 12
In the axial direction.

After mounting the bearings 14 and 14 on the large-diameter side and the small-diameter side in this way, respectively, the respective ends are caulked 11g and 11g, so that the bearing housing 13 and the holding plate 12 are at predetermined positions. It is fixed so that it cannot move axially and cannot rotate.

The taper roller 10 thus manufactured is rotatably supported by the shaft 15 via both bearings 14, 14, and the shaft 15 is supported by the frames 16, 16 at both ends thereof. The shaft 15 is tilted and supported between the frames 16 so that the upper end 2a of the taper roller 10 is horizontal as shown in the figure.

According to the method of manufacturing the taper roller 10 described above, the roller body 11 does not deform the pipe material into a taper shape by swaging as in the conventional case, but cuts the fan-shaped primary materials 11a and 11a. Is a method for manufacturing a taper-shaped roller body 11 by bending the secondary materials 11b and 11b and joining them by laser welding.
The next material 11b has less variation in thickness than the pipe material,
And since it is bent, the roller body 1
The inner and outer diameters of No. 1 can be made uniform with a higher accuracy than ever before. From this, the bearings 14 and 14 can be firmly held without post-processing to align the inner diameters Di and di at both ends of the roller body as in the conventional case, and thus the manufacturing process of the taper roller 10 is greatly simplified. Can be converted.

The butted portion 1 after bending
Since the welding of 1c is performed by laser welding, welding can be performed with almost no generation of welding beads, and therefore the joint can be finished cleanly without any post-treatment, and in this respect also simplification of the process and cost reduction are realized. it can. Further, instead of laser welding, the abutting portion 11c may be joined by TIG welding or other joining means.

Further, the roller body 11 is bent by bending.
Since it is a method of manufacturing, the roller main body 11 having a large taper degree can be easily manufactured and the large taper degree can be obtained by appropriately setting the dimensions of each part of the primary material 11a and the press die for bending. Unlike the conventional swaging process, the same processing force (bending force)
Since it can be manufactured with, there is no increase in equipment cost. Moreover, since the roller body 11 having a large taper degree can be easily manufactured, it is possible to inexpensively provide a curved conveyor that can swivel the luggage W in a small space, thereby contributing to effective use of the space in the factory.

Next, since the roller main body 11 is manufactured by bending, it is not necessary to consider the strength as a raw material as in the case of the conventional swaging, so that an inexpensive thin plate can be used as a raw material. Therefore, the cost of the material can be reduced.

Further, since a large processing force is not required unlike the conventional swaging, it is possible to reduce the cost of the press die for bending.

Further, conventionally, as shown in FIG. 7, each of the bearing housings 4 and 5 is formed in a substantially cylindrical shape, and the diameter thereof is a dedicated product adapted to the inner diameter of the taper roller on the large diameter side. Therefore, it is necessary to prepare bearing housings 5 of various sizes having different diameters according to the type of roller width L to be set, which causes an increase in the number of parts, resulting in an increase in parts management or parts manufacturing cost. there were. In this respect, according to the exemplified manufacturing method, the diameter of the flange portion 12a of the holding plate 12 is manufactured so as to match the maximum diameter of the roller 11, so that the diameter is the same or the inner diameter of the roller body 11 on the large diameter side. It is possible to cut and use the surroundings as appropriate according to
Can be used as a common component for the taper rollers 10 to 10 having various roller widths L set in various ways,
In this respect, the manufacturing cost of the holding plate 12 and the component management cost can be reduced.

Moreover, since the bearing housing 13 is used as a common component on both the large diameter side and the small diameter side, the number of components can be reduced and the manufacturing cost thereof can be reduced also in this respect.

Various modifications can be made to the embodiment described above. For example, although the structure in which the two primary materials 11a are butted to each other has been illustrated, it is also possible to make a method in which one primary material is bent and both ends thereof are butted and joined.

Further, in the illustrated embodiment, the holding plate 12
Although the bearing housing 13 is mounted on the large diameter side of the bearing housing 13, the bearing 14 may be mounted directly on the boss 12b of the holding plate 12 without using the bearing housing 13.

Further, on the small diameter side as well, while half-cutting is performed, the holding plate 12 is cut to an appropriate diameter and the bearing 14 is mounted on the boss portion thereof, and the bearing is positioned and mounted by the half-cutting portion. May be

[Brief description of drawings]

FIG. 1 shows an embodiment of the present invention, (A) is a plan view of one material, (B) is a perspective view of a secondary material, and (C).
FIG. 3 is a perspective view of a roller body formed by joining secondary materials.

FIG. 2 is a view showing details of a half punching portion,
(A) is a longitudinal sectional view taken along the axis, and (B) is (A).
It is a sectional view taken along the line AA of FIG.

FIG. 3 is a view showing a holding plate, (A) is a front view,
(B) is the BB sectional view taken on the line of (A), (C) is a side view.

FIG. 4 is a vertical cross-sectional view of a taper roller showing an assembled state thereof.

FIG. 5 is a plan view of a curve conveyor.

FIG. 6 is a plan view showing a curved conveyor having a large turning radius and a curving conveyor having a smaller turning radius in comparison.

FIG. 7 is a vertical cross-sectional view of a conventional taper roller.

FIG. 8 is a vertical cross-sectional view of a post-processed portion of a conventional taper roller whose end is post-processed, (A) being a large diameter side, and (B).
Indicates the small diameter side.

[Explanation of symbols]

10 ... Tapered roller 11 ... Roller main body 11a ... Primary material, 11b ... Secondary material, 11c ... Butt portion, 11d ... Half punched portion 12 ... Holding plate 13 ... Bearing housing S ... Saving space Di ... Large diameter side Inner diameter Do ... Outer diameter on large diameter side di ... Inner diameter on small diameter side do ... Outer diameter on small diameter side

Claims (3)

[Claims] 1. A method of manufacturing a taper roller for a curve roller, which comprises bending a material cut into a fan shape and joining the abutting portions to manufacture a taper roller body. 2. The method for manufacturing a taper roller according to claim 1, wherein at least the peripheral surface of the taper roller body on the large diameter side is subjected to half punching, and the half punching portion is axially positioned to position the taper roller. A method for manufacturing a taper roller for a curved conveyor, characterized in that a disc-shaped holding plate is mounted on the inner peripheral side of the taper roller, and a bearing is mounted on at least the large diameter side of the taper roller via the holding plate. 3. The method of manufacturing a taper roller according to claim 2, wherein a bearing housing for holding the bearing on the small diameter side is attached to the holding plate, and the bearing housing is shared by the large diameter side and the small diameter side. A method of manufacturing a taper roller for a curved conveyor, characterized by: