RU2244670C1 - Conveyor roller - Google Patents

Abstract

FIELD: mechanical engineering; belt conveyors.

SUBSTANCE: invention can be used in belt conveyors, transporting devices, roll beds, etc. used in different industries. According to invention, roller body is made of secondary composite polymeric material with wooden filler in amount of 10-50% of total mass of mixture. Body is provided with stiffening ribs uniformly spaced over circumference identical to stiffening ribs made on outer surface of roller axle box reinforced from inside metal bushing into which corresponding bearing is press-fitted. Axle box is made of mixture of secondary composite polymeric material of polyamide type with secondary polyethylene in amount of 10-20% of total mass of mixture. Three-channel labyrinth seal with pocket for lubricant is made on end face of axle box pointed inwards the roller body, and on opposite end face trapezoidal section ring groove is made. Said labyrinth seal is made of secondary polymeric material and is provided with bushing with ring trapezoidal bead. Bushing of labyrinth seal is provided with ring projections and cavities of trapezoidal form on surface pointed to roller cover to form clearance for lubrication.

EFFECT: improved operation in chemically abrasive media.

2 cl, 4 dwg, 5 dwg

Description

The invention relates to mechanical engineering and can be used for belt conveyors, conveying devices, live rolls, etc., used in chemical, coal, processing, food, construction and other industries.

Known conveyor roller (A.S. 154872, class B 65 G 30.10, publ. 02.15.1990, BI No. 6), consisting of a metal pipe, bearings, mounted in a housing and installed in the pipe, axis and bearing seals.

The conveyor roller closest in technical essence (SU 541741 p. 1, 03/21/1977, titled sheet, Figs. 1-2s.), Comprising a cylinder-shaped housing, a roller axis, rolling bearings, axle boxes that perform the function of bearing housing, labyrinth seals made of polymer material.

However, the rollers of this design are not resistant to chemically aggressive and abrasive media, as well as to environments with a high moisture and dust content. The components of the rollers react with these saddles and for a short period of operation fail, wedge, creating emergency situations, and cut the conveyor belt.

The authors were faced with the task of developing a conveyor roller with improved performance characteristics when working in chemically aggressive and abrasive media (phosphoric, nitric, acetic acid, ammonia, phosphogypsum, hydrogen fluoride, transport products, their mixtures and dust: nitroammophoska, urea, ammonium nitrate, cement, coal, stone dust, cob), wet and highly humid (washed coal, crushed stone, concrete, cement mortar, molding mixtures of bricks and faience), as well as when exposed to atmospheric conditions (rain, snow, mans, sun), increasing the efficiency of the sealing unit, improving the damping properties of the roller, reducing noise and vibration characteristics, eliminating the occurrence of emergency situations due to the spell of the roller, cutting the tape.

This problem is solved by the fact that in a conveyor roller containing a roller case in the form of a cylinder, a roller axis, rolling bearings, axle boxes that perform the functions of bearing units, labyrinth polymer seals and roller covers, the roller case is made of secondary composite polymer material with wood filler in the amount of 10-15% of the total weight of the mixture. On the inner surface of the roller casing, stiffeners evenly spaced along the entire circumference are identical to the stiffeners made on the outer surface of the axle box. The axle box reinforced from the inside with a metal sleeve into which the rolling bearings are pressed in is made of a mixture of a secondary composite polymer material such as polyamide with secondary polyethylene in an amount of 10-20% of the total weight of the mixture. At the end of the axle box facing the inside of the roller housing, a three-channel labyrinth seal is made with a pocket for lubrication, and an annular groove of a trapezoidal section is made at its opposite end. The labyrinth roller seal is made of recycled material and has a sleeve with an annular trapezoidal collar connected to the said axle box groove to form a clearance for lubrication. The labyrinth sleeve of the roller seal has, on the surface facing the roller cover, ring protrusions and trapezoidal depressions arranged to form a clearance for lubrication with corresponding protrusions and depressions made on the inside of the roller. The roller covers are also made of recycled polymeric material and are pressed onto the ends of the roller housing and have stiffeners on the outer surface that are evenly spaced around the circumference.

The essence of the solution of the problem is illustrated by drawings, in which Fig. 1 shows a general view of a roller in a section, Fig. 2 shows a housing of a roller, Fig. 3 shows a axle box, Fig. 5 shows a roller cover, Fig. 4 - a labyrinth seal sleeve .

The housing of the roller 1 (figure 1, 2) is made in the form of a cylinder from a secondary polymer material with wood filler in an amount of 10-50% of the total weight of the mixture. As a polymeric binder, secondary polymeric materials of the brands polyethylene, polyamide, polypropylene, polyethylene terephthalate, polyvinyl chloride, and also mixtures thereof can be used, and sawdust of various fractions from various tree species can be used as a wood filler. To increase the bearing capacity of the housing of the roller 1 (figure 1, 2) on its inner surface around the entire circumference of the stiffening ribs 2 (figure 1, 2). From the ends of the housing of the roller 1, grooves 3 are made (Figs. 1, 5). To reduce the noise and vibration characteristics of the roller, axle boxes 5 (Figs. 1, 3) are made of secondary composite polymer material of the polyamide type of various grades mixed with secondary polyethylene in an amount of 10-20% of the total mixture weight, internally reinforced with a metal sleeve 6 from the inside (Fig. 1, 3) into which the rolling bearings 7 are pressed (Fig. 1), which, when mounted, are pressed onto the axis of the roller 8 (Fig. 1). From the outer surface of the axle box 5 has stiffening ribs 9 (figure 3), evenly spaced around the entire circumference. The presence of identical stiffening ribs 2 on the inner surface of the housing of the roller 1 (figure 1, 2) and on the outer surface of the axle box 5 ensures their tight connection when assembling the roller. At the end of the axle box 5, facing the inner cavity of the housing of the roller 1 (figure 1), at the same time made a three-channel labyrinth seal 10 (figure 1, 3). Understating the wall thickness of the axlebox 5 creates a pocket for lubricant 11 (Figs. 1, 3). At the end of the axle box facing the sleeve of the labyrinth seal 12 (Figs. 1, 4), there is an annular groove 13 (Fig. 3) of a trapezoidal section, which, when mounting the roller, includes an annular bead 14 (Fig. 4) of a trapezoidal section 10 (Fig. .4) labyrinth seal bushings 12 (Figs. 1, 4), which are made of a secondary polymer material such as polyethylene, polyamide, polypropylene, polyethylene terephthalate. On the surface of the labyrinth seal sleeve 12 facing the roller cover 4 (FIG. 1), there is a hub 15, (FIG. 4) with a hole for pressing on the roller axis 8 (FIG. 1) and two concentric annular projections 16 (FIG. 4) and two depressions 17 (Fig. 4) having a trapezoidal cross-sectional shape, and on its surface facing the axle box 5 (Fig. 1), there is an annular bead 14 (Fig. 4) of a trapezoidal cross-section, which is the same size and form with an annular groove 13 (figure 3), included in conjunction with it so that creates a pocket for lubrication 18 (FIG. 1).

The cover of the roller 4 (1, 5) is made of a secondary polymer material such as polyethylene, polyamide, polyethylene terephthalate. The design of the roller cover 4 provides on the outer surface small stiffeners 19 (Fig. 5), evenly spaced around the circumference, and on the inner surface are three circular annular depressions 20 (Fig. 5) having a trapezoidal cross-sectional shape. The depressions 20 (Fig. 5) of the roller cover 4 (Figs. 1, 5) coincide in size and shape with the protrusions 16 (Fig. 4) of the labyrinth seal sleeve 12 (Figs. 1, 4), creating a clearance 0 between each other during assembly. 1-0.2 mm, which is filled with grease. The outer diameter of the cover of the roller 4 is made shoulder 21 (figure 5). Using the shoulder 21, the cover of the roller 4 (Figs. 1, 5) is pressed onto the annular groove 3 (Fig. 2) from the ends of the housing of the roller 1, the central hole of the cap 4 is mated to the hub 15 of the labyrinth seal sleeve 12 with a clearance of 0.1-0 , 2 mm and, in fact, also serves as a seal. The fastening of the cover of the roller 4 (figure 1) to the housing of the roller 1 (figure 1) is carried out by fixing screws 22 (figure 1). Mounting axlebox 5 (figure 1) to the housing of the roller 1 (figure 1) is the locking pins 23 (figure 1).

The axial displacement of the rolling bearing 7 (FIG. 1) is eliminated by the locking sleeve 24 (FIG. 1), welded during assembly to the axis of the roller 8 (FIG. 1).

The installation of the roller begins with the assembly of the bearing assembly, namely: grease 5 is clogged in the lubrication pocket 11 (Fig. 1, 3) of the axle box (Fig. 1), and then the rolling bearing 7 is pressed into the axle box 5 (Fig. 1). The axle box 5 (Figs. 1, 3) with a rolling bearing 7 (Fig. 1) is pressed from one side into the housing of the roller 1 (Figs. 1, 2), the axle box 5 is pressed in on the axle 8 (Figs. 1, 3) together with the bearing rolling 7 (figure 1). Then, the assembly of the node-axis-axle-box-bearing is pressed into the housing of the roller 1 (Fig. 1, 2), and the opposite end of the axis 8 (figure 1) - into the axle box 5 already pressed into the roller case 1 with the bearing 7. On the axis with both sides put on the locking sleeve 24 (figure 1) and are welded to the axis 8 (figure 1). Grease is filled into the lubricant pocket 18 (Fig. 1), as well as into the annular groove 13 (Fig. 3) of the axle box 5 (Figs. 1, 3). The protrusions 16 and depressions 17 (Fig. 4) of the labyrinth seal sleeve 12 (Fig. 1.4) are lubricated with grease. The hub 15 (figure 1, 4) the labyrinth seal sleeve is pressed onto the axis 8 (figure 1) until it stops with the locking sleeve 24 (figure 1). An annular bead 14 (Fig. 4), which coincides in configuration and size with the annular groove 13 (Fig. 3) of the axlebox 5 (Figs. 1, 3), enters into it with a gap of 0.1-0.2 mm, forming pocket for lubrication 18 (figure 1). Due to the formed pocket for lubrication, the protective properties of the sealing assembly are increased, eliminating the ingress of dust, moisture, and transportation products into the friction-rolling zone. Lubrication from the grease pockets 11 and 18 (FIG. 1) constantly feeds the friction-rolling zone, thus reducing the friction-rolling coefficient, eliminates the occurrence of emergency situations due to jamming of the bearing assembly, reduces noise and increases the operational characteristics of the roller. On the ends of the housing of the roller 1 (Fig. 1, 2), the covers of the roller 4 are pressed in (Figs. 1, 5). The depressions 20 (Fig. 5) of the roller cover (Figs. 1, 5) are aligned with the protrusions 16 (Fig. 4) of the labyrinth seal sleeve 12 (Figs. 1, 4) having the same configuration and create a three-channel labyrinth seal.

The fastening of the cover of the roller 4 (Fig. 1) to the housing of the roller 1 (Fig. 1) is made by the fixing screws 22 (Fig. 1), and the axle box 5 (Fig. 1) is fastened to the housing of the roller 1 (Fig. 1) by locking pins 23 (figure 1).

The manufacture of the main elements of the roller-housing, axle boxes, labyrinth seal bushings of the roller cover from secondary polymer composite materials makes it possible to use the proposed roller in chemically aggressive and abrasive environments with increased dust content and humidity. The quantitative composition for the manufacture of the roller housing is determined depending on the necessary physical and mechanical properties. In the same way, the composition of the mixture (charge) of the composite material for the axle box was determined taking into account the vibro-acoustic characteristics. Physico-mechanical and vibro-acoustic characteristics of the roller casing, axle boxes, are shown in tables 1, 2, 3, 4.

To determine the optimal composition of the material for the roller casing, basic physical and mechanical tests of its bearing capacity were carried out. The results obtained are shown in table 1.

Table 1. No. p / p The tensile strength of the material of the roller housing, MPa The composition of the initial mixture in% Recycled polyethylene: Wood filler 90:10 80:20 70:30 60:40 50:50 1. - during compression 9.0 11.0 15.4 16.6 15.6 2. - in tension 10.5 10.0 9.1 8.8 8.5 3. - with static bending 14.0 15.0 17.5 18.1 17,2

Table 2 shows the forces of the onset of deformation of the roller casing with a size of ⌀127 × 380 mm depending on the composition of the initial mixture.

table 2 No. p / p Indicator kg The composition of the initial mixture in% Recycled polyethylene: Wood filler 1. The force of the beginning of the deformation of the roller casing 90:10 80:20 70:30 60:40 50:50 3990 4230 4670 5126 4770

The results of tests of the material given in tables 1, 2 for the roller casing showed that with an increase in the amount of wood filler in the composition of the initial charge significantly improves its physical, mechanical and load characteristics. However, at a 50% content of wood filler in the total mass of the mixture, a slight deterioration in its properties occurs. At a 10% content of wood filler in the total mass of the mixture of material for the roller case satisfies its operational characteristics. Therefore, to improve the operational properties of the material of the roller casing, the optimal content of wood filler in the total mass of the mixture is 10-50%.

To determine the optimal composition of the material for the axlebox, the main physical and mechanical tests of its bearing capacity were carried out. The results obtained are shown in table 3.

Table 3. No. p / p The ultimate strength of the axle box material, MPa The composition of the initial mixture in% Secondary polyamide: Secondary polyethylene 90:10 85:15 80:20 1. - in tension 55.0 48.5 44.9 2. - during compression 79.3 74.5 71.3 3. - elongation, in% 78 115 107

As can be seen from table 3, the content in the total mass of the mixture of 20% secondary polyethylene slightly reduces the physical and mechanical properties of the material for axle box, and 10% of secondary polyethylene, as material for axle boxes, has the best performance. The content of 10-20% of the filler in the total mass of the mixture fully satisfies its operational characteristics.

Table 4 shows the comparative vibrational characteristics of the rollers: metal (prototype) and made of secondary polymeric materials.

The comparative vibrational characteristics of the rollers shown in Table 4 show that the roller made of secondary polymeric materials has the best properties. The content in the material of the roller case is 10-50% of wood filler, and in the material of the axle box 10-20% of secondary polyethylene, it is possible to reduce the vibration and noise characteristics of the roller made of secondary polymeric materials by 1.5-2 times.

Table 4 No. p / p Roller design Level in 1/3 octave frequency bands, dV 2 4 6 8 10 12 14 16 eighteen twenty 22 24 26 28 thirty 32 6.3 10.0 16,0 25.0 40,0 63.0 100.0 160,0 250,0 400,0 630.0 1000,0 1600,0 2500,0 4000,0 6300.0 1. Metal roller (prototype) fifty 42 47 67 72 81 93 77 82 99 93 81 69 63 57 75 2. Roller from recycled polymeric materials (claimed) 32 25 33 32 35 31 37 38 32 48 33 42 36 36 29th 31

Design features of the roller cover, labyrinth seal bushings, axle boxes with an additional labyrinth seal, as well as the presence of stiffeners on the inner surface of the roller housing and on the outer surface of the axle box provide complete protection of the bearing assembly and the inner volume of the roller from penetration of abrasive material, dust, moisture, transportation products and etc.

The proposed conveyor roller passed a full cycle of full-scale tests in chemically aggressive and abrasive environments at chemical enterprises, in abrasive and dusty environments at cement plants and crushed stone quarries, in humid environments at house-building plants and brick factories. A thorough analysis of field tests of the rollers and their component parts in these environments allowed us to conclude that the rollers of this design exceeded the service life previously used by 1.5-2 times, increased operational characteristics, the possibility of emergency situations when the bearing assembly is jammed, increased reliability of the seal , vibration and noise characteristics are reduced, tape cutting is excluded, the ecology is improved and are recommended for operation at these enterprises.

Based on the foregoing and taking into account the patent information search, we believe that our conveyor roller meets the requirements for inventions and can be protected by a patent of the Russian Federation.

Claims (2)

1. Conveyor roller, containing a roller casing in the form of a cylinder, roller axis, rolling bearings, axle boxes, which function as bearing housing, and labyrinth seals made of polymer material, characterized in that the roller case is made of secondary composite polymer material with wood filler in an amount 10-50% of the total mass of the mixture and on the inner surface has stiffeners evenly spaced around the entire circumference, identical to stiffeners made on the outer surface of the axle box, reinforced inside the metal sleeve, into which the corresponding bearing is pressed into, the axle box is made of a mixture of secondary composite polymer material such as polyamide with secondary polyethylene in an amount of 10-20% of the total weight of the mixture, at the end of the axle box facing the inside of the roller housing, a three-channel labyrinth seal is made with a pocket for lubrication, and at its opposite end an annular groove of a trapezoidal section is made, the labyrinth seal of the roller made of a polymer material is made from a secondary polymeric material and has a sleeve with an annular trapezoidal collar connected to the said axle box with the formation of a clearance for lubrication, the labyrinth seal sleeve of the roller has on the surface facing the roller cover, annular protrusions and trapezoidal cavities arranged with the possibility of forming a clearance for lubrication with corresponding protrusions and depressions made on the inner side of the roller cover, while the covers are made of recycled polymer material and are pressed and the ends of the roller body. 2. The conveyor roller according to claim 1, characterized in that the roller cover from the outer surface has stiffeners evenly spaced around the entire circumference.

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