MXPA96001900A - Idler roll for use in belt conveyor systems - Google Patents

Abstract

There is provided and idler roll for use in belt conveyor systems comprising a shaft and at least two modular sections disposed adjacent to one another surrounding the shaft, the at least two modular sections varying in thickness as measured along an axis of the shaft. There is also provided an idler roll for use in belt conveyor systems comprising a shaft and a molded polymer coating disposed around the shaft, wherein the coating is at least partially tapered in cross section at each end of the idler roll. There is further provided a belt conveyor system for handling bulk material employing idler rolls.

Description

GUIDE ROLLER FOR USE IN BAND CONVEYOR SYSTEMS D E S C R I P C I O N This invention relates generally to guide rollers or also called idler rollers and more particularly to guide rollers used in belt conveyor systems. Guide rollers are typically used in belt conveyor systems to handle bulk or bulky material, such as coal, sand, mechanical devices and the like. As is known in the art, a series of guide rollers may be arranged in a U-shaped manner having a conveyor arranged to transport bulky or bulk material. For example, a first guide roller may be aligned along a horizontal direction and a second guide roller and a third guide roller may extend at an angle (ie, 30 to 45 °) in the same plane that the first guide roller, to form the U-shaped configuration. A plurality of these first, second and third guide rollers may be arranged along the desired path to move bulk or bulky material. When a conveyor is disposed above the plurality of guide rollers, the U-shaped configuration helps prevent spillage of the bulk material from the conveyor. The idler guide rollers or rollers of the prior art have been formed with steel rollers. That is, a steel roller is placed around a central axis that forms the steel guide roller. However, steel guide rollers tend to allow the accumulation of material on the roller, especially when the material being transported is sticky in nature. In addition, the steel guide rollers can wear out quickly when the materials being transported are abrasive substances. To help overcome the disadvantages of steel guide rollers, these rollers have also been formed with an extruded polyethylene cover. With reference to Figure 1, a guide roller 10 having a steel shaft 12 and a steel cover 14 is shown. A polyethylene cover 16 is disposed about the steel shaft 12 and cover 14 by the use of polyethylene discs 18 at each end of the guide roller 10. The air space 20 is present in the region between the polyethylene discs 18, the steel cover 14 and the polyethylene cover 16. Because the polyethylene cover is extruded, it may be necessary to add an additional processing step to smooth the outer surface of the polyethylene cover 16 by a turning or polishing operation. This adds high manufacturing costs. In addition, because the disks 18 are disposed at each end of the guide roller 10, there may be an absence of load support in the central region of the guide roller (ie, in the place of the air space 20). Typically, the idler guide rollers or rollers of the prior art are designed of a certain length for a given application. For example, guide rollers having a size variation of approximately 15.24 centimeters to approximately 1.83 meters are typically used to transport bulky or bulk material. Therefore, a plurality of guide rollers of different dimensions will have to be fabricated to have variations in the size of covers 16 to cover all the desired lengths required. In the past, guide rollers have been formed by combining a plurality of single size polyethylene layers on a steel cover and shaft to form a larger guide roller. However, it is desirable to have flexibility to create a guide roller of a given size based on a series of modular sections that can vary in length. This will allow the formation of a guide roll whose length is not an integral multiple of the polyethylene cover of a single size. That flexibility will allow for incremental differences in the sizes or dimensions of the desired guide rollers. As a result, the use of modular sections may allow fewer parts to be saved to form a guide roll of a desired length. Because the typical polyethylene guide rolls of the prior art are formed by placing a layer of extruded polyethylene on a steel layer, they have edges 22 that are perpendicular in section. When the aforementioned U-shaped configuration is formed, there may be a sharp point of contact between two adjacent guide rollers and the conveyor belt there disposed. These sharp tips can decrease the life of the conveyor belt. Therefore, it is desirable to have a polyethylene guide roll that does not have perpendicular edges that affect the life of the conveyor belt there placed. A guide roller for use in belt conveyor systems comprising an axle and at least two modular sections disposed adjacent to each other surrounding the axle is provided, the at least two modular sections varying in thickness, when measured along the length of the axle. a central line of the axis. Also provided is a guide roller for use in belt conveyor systems comprising an axis and a molded polymer coating disposed about the axis, wherein the coating is at least partially tapered in section at each end of the guide roller. There is further provided a belt conveyor system for handling bulk or bulky material comprising a plurality of guide rollers arranged along a given direction and a conveyor belt disposed on the plurality of guide rollers, wherein each of the plurality of guide rollers comprises an axis and at least two modular sections formed of polymer material arranged adjacent to one another; the at least two modular sections vary in thickness when measured along the center line of the axis and the modular sections surround the axis.

Figure 1 is a front elevational view of a prior art polyethylene guide roller, with a view partially cut away from the interior portions of the guide roller. Figure 2 is a perspective view of a system for handling bulk or bulky material according to the principles of the present invention, with a portion of the conveyor belt removed for purposes of illustration. Figure 3A is a front elevation view of a guide roller according to a first preferred embodiment of the present invention with a partial sectional view of the interior portion of the guide roller and Figure 3B shows an enlarged view of a shore conical alternative. Figure 4 is a front elevational view of a guide roller according to a second preferred embodiment of the present invention, with a partial sectional view of the inner portion of the guide roller. Figure 5 is a side elevational view of the guide roller of Figure 4. Figure 6 is a sectional view of the end modular section of Figure 4. Figure 7 is a side elevational view of the modular section at the end of Figure 6. Figure 8 is a sectional view of the central modular section of Figure 4. Figure 9 is a side elevational view of the central modular section of Figure 8; and Figure 10 is a partial sectional view of the steel hull used in the present invention.

With reference to Figure 2, a conveyor system 2 for handling bulk or bulky material according to the principles of the present invention is shown. Similar parties have been similarly numbered for purposes of clarity. A plurality of guide rollers 10A, 10B and 10C are aligned along a given plane forming a U-shaped configuration. Each of the guide rollers 10A, 10B and 10C are connected by grease tubes 13, as is common in the industry. Also as is common in the industry, the guide rollers are connected to a supporting structure or base angles by the use of the end brackets 17 and central brackets 19. In addition, a conveyor belt 21 may be disposed on the guide rollers for transporting bulky or bulk material. Referring also to Figure 3A, a guide roll formed in accordance with a first preferred embodiment of the present invention is shown. In this embodiment, a polyethylene cover or coating 16 is disposed about an axis 12 and steel cover 14. Preferably, the polyethylene material used is a high density polyethylene, such as the polyethylene material number 04452N manufactured by General Polymers. However, other suitable polymer materials can also be used. As is common in the industry, an adjusting nut 30 is provided at each end of the guide roller 10. The bearing assemblies 32, which can be tapered roller bearings, are also provided at each end of the guide roller 10. The adjusting nut 30 fixes the preload of the tapered roller bearing assemblies 32. The bearing assemblies 32 allow rotation of the guide roller 10 and transmit the charge of the polyethylene cover 16 to the shaft 14. In addition, a sealing assembly 34 is provided provided to help protect the bearing assemblies 32 from contaminants. The seal assembly 34 may be a triple labyrinth seal assembly. An assurance pressure ring 36 can be employed to secure the polyethylene cover 16 in place. Preferably, the securing pressure ring 36 is formed of steel. Referring also to Figure 10, a partial sectional view of the steel helmet or cover 14 is shown. The details of the opposite ends of the steel cover 14 are similar to the end shown. The central portion 40 of the steel cover 14 is preferably the thickest in section. The portion 42 of the steel cover 14 disposed around the bearing assembly 32, preferably it is slightly smaller in section than the central portion 40. In addition, the end portion 44 of the steel cover 14 is preferably slightly smaller in section than the portion 42, allowing insertion of the sealing assembly 34. A bevel 46 may be located on the edges of the end portion 44. The steel cover 14 can be symmetrical about the central line 246. Referring again to Figure 3A, the edges 22 of the guide roller 10 are tapered in section. Preferably, the taper results in a curved section, as shown in Figure 3A. The radius of curvature of the edges may be such that the ends 23 do not have a substantially flat surface. Preferably, however, the radius of curvature is 3.05 millimeters (0.12 inches). Alternatively, the edges may be conical providing a bank 22 'as shown in Figure 3B. By having edges 22 that are conical or curved in section there can no longer be a sharp contact point between two adjacent guide rollers, such as guide rollers 10A and 10C of Figure 2. As a result, the life of the conveyor can be extended. 21 of band. In addition, the curved edges 22 can help to spill material that would otherwise accumulate, if the edges were perpendicular in section.

Referring now to Figure 4, a second preferred embodiment of the present invention is shown, the second preferred embodiment differs from the first preferred embodiment in that a plurality of modular sections of the described polyethylene shell is provided, instead of a single one. piece of material. Referring also to Figures 6 and 7, an end modular section 50 having curved edges 22 is shown. A modular end section 50 has an outer upper surface 52 and outer side surfaces 54, 56 and 58. The modular end section 50 further has an internal surface 60 which is disposed against the steel cover 14. In addition, an inner surface consists of the surfaces 62, 64 and 66. Furthermore, a bevel is located between the surface 66 and the surface 60. Preferably, the inner surface is shorter in length than the end 70 of the outer surface by a distance 68, measured along a central line 78 of the axis. The general region disposed between the surface 62 and 54 may be referred to as the cover or layer 72. The region disposed between the surface 64 and the surfaces 56 and 58 may be referred to as the core 74. In addition, the region disposed between the surfaces 66 and 58 it can be referred to as the hub 76. Preferably, the thickness of the cover 72 is larger than the thickness of the hub 76 measured along the line 78 of the shaft. In addition, preferably the thickness of the hub 76 is larger than the thickness of the web 74 measured along the line 78 of the shaft. With reference to Figure 8, a central modular section 90 is shown. The central modular section may vary in measured length along the center line of the shaft as will be described. As indicated in Figure 4, the central modular section 90 is provided with a suffix of A, B and C to indicate the variation of sizes or dimensions of the modular section 90. A given central modular section 90 has an outer upper surface 92 and side surfaces 94, 96, 98 and 100, 102, 104, as shown. The modular section 90 further has an internal surface 106 which is disposed against the steel cover 14. In addition, a first bevel 108 is located between the surface 106 and the surface 98 and a second bevel 110 is located between the surface 106 and the surface 104. Preferably, the internal surface 106 has a shorter length than the outer surface 92 by a distance 112 at each end, as measured along the axis 78. As seen from Figure 8, the central modular section 90 has a section configured as I. Preferably, the dimensions of the central modular section 90 are symmetrical around a central axis 120. The general region disposed between the surface 100 and 94 may be referred to as the cover or layer 114. The region disposed between the surface 102 and the surface 96 may be referred to as the core 116. In addition, the region disposed between the surface 104 and 98 may refer to as the hub 118. Preferably, the thickness of the cover 114 is larger than the thickness of the hub 118 measured along the center line 78 of the shaft. In addition, preferably the thickness of the hub 118 is larger than the thickness of the web 116 measured along the centerline 78 of the shaft. The cross section of the hub 118 is smaller than that of the cover 114 so that the surfaces 92 of the covers 114 of the adjacent modular sections 90A, 90B and 90C are flush with each other when the modular sections are connected to each other, as shown in Figure 4. Similarly, the hub section 76 of the modular end section 50 is smaller than the cover 72 of the end modular section 50 so that the surface 52 of the cover 72 and the surface 92 of the cover 114 of the central modular section 90 are flush with each other when connected. An example of the dimensions of a guide roller 10 with a diameter of 12.7 cms. (5 inches) constructed in accordance with a preferred embodiment of the invention, are shown in Figures 6 to 9. With reference to Figures 6 and 7, the dimensions of the modular end section 50 can be as follows: dimension 200 is 9.52 cms. (3.75 inches), the dimension 202 is 6.35 cms. (2.50 inches), the dimension 204 is 8.20 cms. (3.23 inches), dimension 206 is 9.52 cm. (3.76 inches), the dimension 208 is 1.12 cms. (0.44 inches), dimension 210 is 0.30 cms. (0.12 inches), the dimension 212 is 3.81 cms. (1.50 inches), dimension 214 is 2.39 cms. (0.94 inches), dimension 216 is a radius of 0.30 cms. (0.12 inches), dimension 218 is a 45 ° bevel of 0.15 cms. (0.06 inches), dimension 220 is a radius of 0.63 cms. (0.25 inches), dimension 222 is 0.25 °, dimension 224 is 12.70 cm. (5.00 inches) and the dimension 226 is 4.93 cms. (1.94 inches). In addition, the dimensions of the central modular section 90C, as illustrated in Figure 4, are referred to in Figures 8 and 9. Specifically, the dimensions for the central modular section 90C may be as follows: dimension 228 is 9.52 cms. (3.75 inches), the dimension 230 is 6.35 cms. (2.50 inches), the 232 dimension is 5.08 cms. (2.00 inches), dimension 234 is 4.44 cms. (1.75 inches), dimension 236 is 1.27 cms. (0.50 inches), dimension 238 is a radius of 0.63 cms. (0.25 inches), dimension 240 is a 45 ° bevel of 0.15 cms. (0.06 inches), dimension 242 is 12.70 cms. (5.00 inches), and dimension 244 is 4.93 cms. (1.94 inches). Preferably, the dimensions for the central modular sections 90A and 90B are the same as those of the central modular section 90C, except that the dimensions for the width of the hub 98 and the cover 94 may vary. For example, for the modular section 90B the length of the surface 92 measured along the axis 78 can be 3.50 cms. (1.38 inches) instead of 5.08 cms. (2.00 inches) and the length of the surface 106 can be 2.84 cms. (1.12 inches) instead of 4.44 cms. (1.75 inches). In addition, for the modular section 90A, the length of the surface 92 may be 5.71 cms. (2.25 inches) instead of 5.08 cms. (2.00 inches) and the length of the surface 106 can be 5.08 cm. (2.00 inches) instead of 4.44 cms. (1.75 inches). A plurality of the modular sections 90 may be arranged to provide a guide roller 10 of the desired length. For example, lengths of 15.24 cms. at 182.88 cm (1/2 'to 6') or larger can be achieved in accordance with the principles of the present invention.

As the dimensions of the steel cover 14, for a steel cover 14 with a diameter of 5.08 eras. (2 inches), the cross section of the central portions 40, 42 and 44 can be 0.40 cms. (0.156 inches), 0.28 cms. (0.1115 inches) and 0.25 cms. (0.098 inches), respectively, as shown in Figure 10. In addition, the length of the portion 44 is preferably 1.67 cms. (0.656 inches) in order to properly allow the insertion of the sealing assembly 34. In addition, the length of the portion 42 is preferably 1.61 cm (0.633 inches) to allow insertion of the bearing assembly 32. The length of the central portion 40 depends on the size of the guide roller 10 desired by the user. That is, the length of the central portion 40 is the desired length of the guide roller 10 minus twice the value of both lengths of the portions 42 and 44. In addition, the bevel 46 can be a 0.06 X 30 ° bevel. Preferably, the outer diameter of the steel cover 14 is slightly larger than the internal diameter of the modular sections (i.e., the length between the internal surfaces 60 of the modular end section 50 or internal surfaces 106 of the section 90. For example, when the outer diameter of the steel cover is 5.08 cm (2 inches) the internal diameter is preferably 4.93 cm (1.94 in.) This allows an interference fit between the modular sections and the shaft Although 3 different width dimensions have been described for the central modular sections 90, any number of configurations of the central modular section 90 can be used to construct the desired guide roller, (i.e., 4, 5 or 10 or more different configurations.) In addition, although a guide roller with a diameter of 12.70 cm (5 inches), guide rollers having a diameter has been shown for purposes of illustration, or different can be easily constructed by, for example, increasing the length of the web portion along the axis 120 when a guide roll has a larger diameter, if desired. In addition, the webs or reinforcements 74 and 116 provide load support for the respective covers or layers 72 and 114. As a result, the webs 74 and 116 help prevent deformation of the covers 72 and 114 that may otherwise result from loads provided to the guide roller 10. With reference also to Figures 4 and 5, preferably the covers 72 and 114, the webs 74 and 116 and the hubs 76 and 118 of the modular end section 50 and the central modular section 90, respectively, have similar dimensions when they measure along an axis transverse to the axis 78. The hubs 76 and 118 provide support for the covers 72 and 114 through the webs 74 and 116. The modular sections 50 and 90 are injection molded parts. The modular sections 50 and 90 are placed on the steel cover 14 using a large hydraulic cylinder, such as a hydraulic cylinder manufactured by Thom ins-Johnson having a hole of 12.7 cm. (5 inches), a bar of 7.62 cms. (3 inches) and a race of 325.0 cms. (128 inches), the race is mounted horizontally instead of vertical. The hydraulic cylinder force adjusts the modular sections on the steel cover. After the modular sections have been forcibly adjusted, the bearing assembly 32, the securing pressure ring 36, the sealing assembly 34 and the adjusting nut 30 can be assembled. The securing pressure ring 36 can be formed of steel and help ensure that the modular sections 50 and 90 are secured in place. It will be recognized that although the present invention has been described in connection with its preferred embodiments, those skilled in the art can develop a wide variety of structural details without departing from the principles of the invention. Therefore, the attached clauses have been constructed to cover all equivalences that fall within the true scope and spirit of the invention.

Claims (19)

R E I V I N D I C A C I O N S

1. - A guide roller for use in belt conveyor systems characterized by an axle and at least two modular sections arranged adjacent to each other, these modular sections surround the axle; where the at least two modular sections vary in thickness when measured along a centerline of the axis.

2. The invention according to clause 1, characterized by a first modular section arranged around one end of the shaft, a second modular section arranged around an opposite end of the shaft and a third modular section disposed between the first modular section and the second modular section; the second modular section comprises a hub arranged on the shaft, a cover and a core or reinforcement disposed between the hub and the cover, this core has a smaller thickness than the cover and the hub, when measured along the center line From the axis.

3. - The invention according to clause 2, characterized in that the cube has a smaller thickness than the cover, when measured along the axis.

4. The invention according to clause 1, characterized in that the guide roller comprises a plurality of modular sections, at least three of the plurality of modular sections vary in thickness, when measured along the axis center line.

5. The invention according to clause 1, characterized by a first modular section arranged around one end of the shaft and a second modular section arranged around an opposite end of the shaft; the first and second modular sections are at least partially curved in section at each end of the guide roller.

6. The invention of clause 5, further characterized by a pressure ring, wherein the first and second modular sections comprise a hub arranged on the shaft, a cover and a reinforcement or core arranged between the hub and the cover; the core has a thickness less than the cover and the hub, when measured along the center line of the shaft and the press ring is disposed against the hub and at least a portion of the core along an outer portion of the hub. the first and second modular sections.

7. The invention according to clause 1, characterized in that each of the modular sections comprises a pre-molded polyethylene material.

8. - A guide roller for use in belt conveyor systems, characterized by an axis and a molded polymer coating disposed about the axis; wherein the coating is at least partially tapered in section at each end of the guide roller.

9. The invention according to clause 8, characterized in that the conical section is a curved section.

10. The invention according to clause 9, characterized in that the molded polymer coating comprises polyethylene and has at least two modular sections; the at least two modular sections have unequal lengths, when measured along the center line of the axis.

11. The invention according to clause 10, further characterized by a first modular section arranged around an end of the shaft, a second modular section arranged around an opposite end of the shaft and a third modular section disposed between the first modular section and the second modular section; the second modular section comprises a hub disposed on the shaft, a cover and a core reinforcement disposed between the hub and the cover; The soul has a thickness smaller than the cover and the cube, measured along a central axis line.

12. - The invention according to clause 11, characterized in that the cube has a thickness less than the cover when measured along the axis.

13. The invention according to clause 10, further characterized by a first modular section arranged around one end of the shaft and a second modular section arranged around an opposite end of the shaft; each of the first and second modular sections is at least partially curved in section at each end of the guide roller.

14. - The invention of clause 13, further characterized by a pressure ring, wherein the first and second modular sections comprise a hub arranged on the shaft, a cover and a reinforcement or core arranged between the hub and the cover; the core has a thickness less than the cover and the hub, when measured along the center line of the shaft and the pressure ring is disposed against the hub and at least a portion of the core along an outer portion of the hub. the first and second modular sections.

15. A belt conveyor system for handling bulk or bulky material, characterized by a plurality of guide rollers arranged along a given direction and a conveyor belt disposed on the plurality of guide rollers, wherein each of the plurality of guide rollers comprises an axis and at least two modular sections formed of polymer material disposed adjacent to each other; the at least two modular sections vary in thickness when measured along the center line of the axis and the modular sections surround the axis.

16. The invention according to clause 15, characterized in that each of the plurality of guide rollers comprises a first modular section arranged around one end of the shaft, a second modular section arranged around an opposite end of the shaft and a third modular section disposed between the first modular section and the second modular section; the second modular section comprises a hub arranged on the shaft, a cover and a reinforcement or core arranged between the hub and the cover; The core has a smaller thickness than the roof and the cube, when measured along the centerline of the axis.

17. The invention according to clause 16, characterized in that the cube has a thickness less than the cover when measured along the axis.

18. The invention according to clause 15, characterized in that the modular sections comprise polyethylene.

19. The invention according to clause 15, characterized in that each of the plurality of guide rollers comprises a first modular section arranged around an end of the shaft and a second modular section arranged around an opposite end of the shaft; each of the first and second modular sections are at least partially curved in section at each end of the guide roller. SUMMARY A guide roller is provided for use in belt conveyor systems comprising an axle and at least two modular sections adjacent to each other surrounding the axle; At least two modular sections vary in thickness when measured along the centerline of the axis. Also provided is a guide roller for use in belt conveyor systems comprising an axis and a molded polymer coating disposed about the axis, wherein the coating is at least partially tapered in section at each end of the guide roller. A belt conveyor system is also provided to handle bulk or bulky material that employs the guide rollers.