RUBBER SPIRAL-STRAIGHT GUIDER-CLEANER FOR RUBBER CONVEYOR BELTS
Field of the invention
Present invention is generally related to the field of traffic and transportation, i.e., field of transport and storage devices used in a particular handling or treatment of articles or materials, and precisely to the field of transport and storage devices. In a broader sense, present invention may belong to the field of mining, where are used transporting systems with rubber conveyor belts for conveying bulk, sticky and adhesive materials in an open cast and in under-ground mines as well. The invention is related to construction which has upper supporting rollers and lower return rollers on which is leaned rubber conveyor belt in working and return run.
According to the International Patent Classification (IPC), subject of the invention is classified and designated by basic classification symbols: B 65 G 39/06 which include roller covers which enable shock absorbing, B 65 G 39/073 which include adjustment of roller covers, especially for cleaning of belts and B 65 G 39/12 which include arrangement of the rollers installed onto supporting construction.
Technical problem
Technical problem which is solved by the subject invention is how to make construction of set of rolls of the belt conveyor, where rolls would function as a guider, cleaner and shock absorber, and would provide continual rectilinear course of the belt and effective and facilitated cleaning of the belt, which would substantially solve the problem of disturbance of balance of forces and deviation from linear course of conveyor belt and substantially would decrease cleavage and tearing of rubber and technical fabrics, would decrease wearing - damage of protective edges and rubber covers, where there will be no waste of material, working life of both rolls and belt would be increased multiply, would be accomplished substantial productive and financial effects through considerable savings in any sense, would
be reduced danger of fire, would be provided important contribution to ecology and would be obtained lower price of raw material and production.
Other important function of annular roll according to the invention is to be carried toward middle of the conveyor, which solves previously mentioned problem and by which is obtained reduced cleaning of the middle of conveyor belt and also reduced deposition of material under the conveyor, and thus filling of a system of rolls and conveyor belt is avoided.
Known state of the art
Conveyor rubber endless belts represent one of the mostly used conveyor systems. Belt conveyors transport bulk material or piece goods on horizontal or slightly slanting belts, which at the same time represent carrying and tensile parts of the conveyor. These conveyors have wide and various use in the mining, metallurgic and chemical industry, in building and earth works, in food industry, agriculture, storage and traffic, i.e., in all cases where is involved transportation of piece goods, such as bags, trunks, packages and the like. In practice, conveyor rubber endless belts have been shown as irreplaceable, especially for:
• Transport of mining rubbish (refuse ore) in coal open-pit mining,
• Transport of coal to thermal power station and garbage dump,
• Transport of non-metallic raw materials,
• Transport of clay.
In industry, belt conveyors can be used as working stands (production on the conveyor belt). This kind of the conveyors may be used for low mass throughputs and relatively short distances, for high throughputs (to 40 000 t/h) of masses and long distances of transportation (even to 100 km), whereby these conveyors was shown to be very economic transportation devices for long distances. Depending on type of material which is transported, distance to which it is transported, conditions of exploitation and other factors, conveyor belts are made in different dimensions and qualities. Basic elements of the transportation system are: conveyor rubber endless belt, operating drum, return drum, device for belt tightening, carrying rollers (rolls), return rollers (rolls), deflection drum and belt cleaner.
Upper, working part of the belt, is usually moved onto carrying rollers, while lower "wastage" part of the belt is moved onto return rollers which support belt in its return run, so that belt, no matter of its weight, would not tighten and tear, and thus would not damage conveyor. Return conveyor rollers are made as: straight - steel return rollers with ability to clean the belts, return rollers with self-cleaning and return guiding rollers.
In the case of conveyor belts which work in extremely heavy-duty conditions, such as transportation of coal and clay in the open air and under the influence of weather conditions of all kinds, transported material is deposited and adhered: earth, clay, coal, send, cement and combination of all above stated. These materials are abrasive, and presently, return rollers are mostly made as return rollers with ability to clean the belt by use of rubber rolls which are based on steel tubular rollers, onto which rubber wedge-shaped rings - discs are mounted. Rolls are placed in a distance of from 3 to 6 m, and conveyor belt is always leaned onto protruding rubber rings. Purpose of these rings is to remove deposited layers, i.e., to clean the belt during return run. These rings - discs are mostly made of rubber material (hardness about 60 ShA) or of steel which is more suitable because of reduced wasting of the rings. Disadvantage of steel rings is that these rings generate wearing of the belt more quickly. It is known solution, wherein rubber rings are placed in a row at circumference of the cylinder. Rings are made as a full profile and in a cross-section they are in the shape of trapezoid with rounded top, but known are solutions where rings also have other geometric forms. Commonly, in cases where it is required that roller works with lower number of rings, between rollers are placed distance rings. Rings are secured from falling out from the cylinder by lateral delimiters which are weld up to cylinder.
Also, it is known that in the case of belt conveyors with rollers, there are constructions with two, three and five rollers placed and lodged to each other under suitable angles. As a result of this kind of slanting way of placing rollers, fluxion of grease from bearings occurs, and as a result of medium in which these rollers work, they are exposed to external influences of impurities and humidity, which are the causes for decreased lifetime of bearings and sealers and thereby roller itself. Time life of rollers or set of rollers is defined according to multiple
factors such as a way of sealing, time life of bearings, repair, working medium and load density.
Technical disadvantages of known solutions, i.e., rubber rings or rolls are numerous:
• As conveyor belt by its wider side is leaned onto protruding rubber rings during exploitation, incision of lines into belt occurs, on places of contact with rings due to strong and constant pressure and friction, i.e., recesses are incised longwise the belt, which during the time results in tearing and cleavage of a rubber or technical fabric,
• Rolls with rings does not provide continual rectilinear course of the belt, because the belt, under the influence of tensile, lateral, centrifugal and vertical forces, which arise under the influence of materials which are adhered on the belt, drums and rolls, tend to exit from equilibrium and glide toward lateral sides, and wearing of belt edges occurs,
• Between the rubber rings are generated deposits of transported material, whereupon some parts of the belt are moved upright, which also has influence on disturbances in equilibrium, i.e., on rectilinear course of the belt, wherein deviation from rectilinear course causes waste of material.
• More difficult cleaning of belts from adhered materials,
• Increased number of stoppages and engagement of manpower for removing stoppages and cleaning of systems from adhered material,
• Extremely short time life, as rings are quickly wasted and therefore they frequently have to be replaced with new ones,
• Initially, they have high cost price,
• They have great mass and therefore great rotary mass,
• Ecologically non-regulated use of old rubber rings,
• In the case of damage, rubber rings are flammable and they easily burn.
Essence of the invention
Above stated disadvantages of known solutions are removed with rubber spiral-straight guider-cleaner for rubber conveyor belts. Rubber spiral-straight guider-cleaner for rubber conveyor belts provides continual and balanced rectilinear course for rubber conveyor belts. It
comprises two rubber thread spiral-straight rolls with left and right thread, which are, by their axis and spirals with straight sets slanted toward the axis of the conveyor belt. As a core, spiral guider-cleaner have steel metallic roll with bearings onto which it is pulled on as a cover. Mounting of rubber spiral-straight guider-cleaner for rubber conveyor belts is done by special device with pneumatic cylinder and with decreased diameter of internal rubber part between metallic and rubber part, whereby tight connection is provided without subsequent sticking or by installing securing pin.
Rubber spiral-straight guider-cleaner for rubber conveyor belts comprises two rubber thread rolls (left spiral-straight set and right spiral-straight set), which are mounted onto common carrier. Angle of a bottom of the belt is in function of use and construction of conveyor itself and it depends of geometrical characteristics of rubber spiral-straight guider-cleaner. Length of the roll is adjustable to the width of the rubber conveyor belt, by combination of segments of different lengths, by which optimal length of rubber spiral-straight guider-cleaner is obtained, which is in the function of conveyor belt width. Rubber spiral-straight guiders- cleaners by their rotation around their axis produce lateral tensile forces which are regularly located at the surface of the conveyor belt according to pattern of fish-bone and in rectilinear direction which is made by straight roll.
Set with rubber guiders-cleaners obtains drive from conveyor belt itself, so for function of the set there is no need for mounting separate driving group with electromotor and reductor. It is important that in proper mounting, rubber rolls abut conveyor belt, i.e., conveyor belt pushes the same. Intensity of pressure of the belt to the rolls is in function of weight and adhesiveness of transported material. Advantages of this invention are mainly implied in a fact that there is provided balance of effects of all forces during moving of conveyor belt (tensile, lateral, centrifugal, vertical forces, etc.) into desired direction. By its rotating around its axis, working surface (contact surface) of rubber spiral-straight guider-cleaner effectively cleans adhesive material from the belt from the whole surface, which is the second important function of this product - so called self-cleaning function, and during this it does not damage conveyor belt by engraving into outer cover of the conveyor belt.
Rubber spiral-straight guider-cleaner for rubber conveyor belts, according to the invention, is placed onto belt conveyor which is composed of a rigid frame composed of a stand and two vertical pillar carriers. In the upper part of the conveyor, onto holders which are fixed onto carriers, inside bearings, are rotatory lodged three rollers onto which is leaned upper carrying arm of the conveyor belt. Lower return arm of the belt of the conveyor is leaned onto set of rubber thread rolls according to the invention, which are through holders, lodged onto carriers. Said rolls are made of metallic cylinders which at their outer surface have firmly placed rubber spiral and/or rings, where one of the rolls according to the invention is made with left thread as left spiral-straight roll, while the other roll according to the invention is made with right thread, as right spiral-straight roll.
Application also contains multiple variants of realization of ways-combinations for mutual placement of the rolls according to the invention.
According to all above stated, rubber spiral-straight guider-cleaner for rubber conveyor belts, according to this invention, in relation to known rolls-rollers of this type, has more advantages of which the most important are the following:
• Simplicity of solution,
• Increased performance in transportation,
• Decreased stoppages which may appear as a result of belts run-off, adhesion of material onto elements of a transport system,
• Decreased need for engagement of manpower,
• Alleviated maintenance,
• Substantially decreased costs of supplies and amount of wasted material,
• In the case of damage, reduced risk of fire,
• Multiple times increased time life of roller,
• Low production price - inexpensive technical solution and
• High ecological level - less harmful for environment.
Short description of the drawings
With purpose of easier understanding of the invention, and also for illustrating how it can be realized practically, author makes reference to enclosed drawings, where:
Fig. 1 shows roll of rubber spiral-straight guider-cleaner for rubber conveyor belts, according to the invention, with left thread.
Fig. 2 shows roll of rubber spiral-straight guider-cleaner for rubber conveyor belts, according to the invention, with right thread.
Fig. 3 shows schematic belt conveyor in a cross-section with basic way of placing the rolls from Figs. 1 and 2, in return run of the belt.
Fig. 4 shows a variant of the way of placing the rolls from the Fig. 3 at two-sided trough-shaped conveyor belts.
Fig. 5 shows the third variant of the way of placing the rolls from Figs. 1, 2 and 3 onto the frame at two-sided trough-shaped conveyor belts.
Fig. 6 shows a variant for obtaining horizontal spiral-straight roll at in a straight-line guided conveyor belts in return run of the belt.
Detailed description of the invention
Rubber spiral-straight guider-cleaner for rubber conveyor belts in the case of belt conveyors, according to the invention and Figs. 1, 2 and 3, is generally comprised of two rubber rollers- rolls (left and right). These rolls on their outer surface have combinations of protruding profiles which in a cross-section are in the shape of trapezoid, where on one part of the roll there is protruding profile in the shape of spiral-worm and on the other part of the roll there is protruding profile in the shape of straight rings. According to this embodiment of realization, Fig. 1, rubber spiral-straight guider-cleaner is made with left thread, as left spiral-straight roll 1, while according to the second embodiment, Fig. 2, rubber spiral-straight guider-cleaner is made with right thread, as right spiral-straight roll 2.
Rubber left spiral-straight roll 1, Fig. 1, is made of metallic cylinder 1' which on the part of its outer surface, on its left side, has protruding profile in the shape of a spiral 1" with left thread, which in a cross-section is in the shape of trapezoid. On the other part of outer surface
of the roll 1, on its right side, there are multiple mutually parallel protruding profiles-rings 1'" which in a cross-section are also in the shape of trapezoid.
Rubber right spiral-straight roll 2, Fig. 2, is made of metallic cylinder 2' which on the part of its outer surface, on its left side, has protruding profile in the shape of a spiral 2" with the right thread, which in a cross-section is in the shape of trapezoid. On the other part of the outer surface of the roll 2, on its right side, there are multiple mutually parallel protruding profiles-rings 2'" which in a cross-section are also in the shape of trapezoid. Cylinders V, T are made with internal diameter du, and diameter of outer wall dl. Rubber spirals 1", 2" and the rings 1'", 2'" are made with outer diameter Ds, depth b, step k between the threads, i.e., rings and angle α of the spirals 1", 2" in relation to vertical plane.
The following Table shows dimensions in a preferred range, and represented dimensions are related only to one preferred embodiment of the invention:
The basic idea of the invention is that length of spiral-straight rolls 1 and 2, which is in the function of width of rubber conveyor belt, is adjustable and is obtained by combination and production as a whole by vulcanization in a tool with required number of segments of different lengths according to required dimension. Rubber parts of the segments are mutually connected by hot and cold vulcanization which represent essence and advantages of the invention. In this way, rubber spirals 1", 2", i.e., rubber straight rings 1'", 2'" are mounted onto metallic cylinders 1', 2' as a cover, using special device with pneumatic cylinder. Tight connection between the rubber spirals-rings and metallic cylinder is obtained by overlapping which enables tight connection between the metal and rubber. Previously mention is provided by precisely defined decreased diameter in a range of from 0.5 to 2 mm depending on diameter. This prevents sliding and non-continuous course of the spirals 1", 2", i.e., of straight rings 1'", 2'", in the case where on metallic cylinder 1', 2' are multiple segments set in a row. From the previous it is clear that there is no need for additional sticking, connecting with a pin or securing in some other way connection between the spiral-rings and cylinder.
Disassembling, i.e., replacement of spent rubber spirals 1", 2", i.e., rings 1'", 2'" of rolls of rubber spiral-straight guiders-cleaners is done by the same device as for assembling.
Rubber spiral-straight rolls 1 or 2 the most preferably are made from special anti-abrasive rubber mixture 65±5 ShA in normal and oil resistant quality.
To match resultant of tensile forces which are result of screwing movements of spiral-straight rolls 1 or 2, with axis of rectilinear movement of the conveyor belt, guider-cleaner for conveyor belts is characterized by that left and right rubber spiral-straight rolls 1, 2, are installed symmetrically in relation to vertical longitudinal plane of symmetry of the conveyor and onto the same carrier of the set.
As a result of this kind of construction of thread rolls, left and right thread rubber roll are making together axial force which matches to line and direction of tensile force of the conveyor belt, while lateral forces are cancelled as they are of the same line, but of opposite directions.
According to Fig. 3, and Figs. 1 and 2, one left spiral-straight roll 1 and one right spiral- straight roll 2 are forming set of the spiral-straight guider-cleaner for the conveyor belt. According to the invention (Fig. 3), the belt conveyor 3 is shown schematically and in a cross- section, and in standard case is made of a rigid frame composed of a stand 4 and two vertical pillar carriers 4'. In the upper part of the conveyor 3, onto holders 5 which are fixed onto carriers 4', inside the bearings 8 are rotatory lodged three rollers 6. Onto these three rollers 6 is leaned upper carrying arm 7 of the conveyor belt. Middle roller 6 is placed horizontally, and left and right rollers 6 are placed under certain inclination in relation to the middle one, and carrying arm 7 of the conveyor belt has grooved profile. In its return run, belt is, by its lower return arm 10, leaned onto set of spiral-straight guider-cleaner, i.e., onto rubber spiral- straight rolls 1 and 2, according to the invention and Figs. 1 and 2. Left and right spiral- straight rolls 1, 2 are, by their outer ends and through the bearings 8, rotatory lodged onto holders 9 which are fixed onto pillar carriers 4'. Rolls 1, 2 are, by their internal ends, mutually closely connected through the bearings 8' or in some other known way. Bearings 8' are
placed inside the carriers, for example, fixed to the frame of construction of the conveyor 3. Rolls 1 and 2 are mutually placed under the angle, i.e., under the inclination in relation to the vertical plane of symmetry of the conveyor 3, so that arm 10 of the belt obtains the shape of the letter V. Also, rolls may be placed by their central axes under certain angle in relation to longitudinal axis of the conveyor. By their rotating around their axis, spiral-straight guiders- cleaners, which are mutually placed in a distance of preferably 0.6 m, produce lateral tensile forces which are regularly located on the surface of the conveyor belt and according to the system of "fish-bone". Surely, influence of these forces in a system of rolls 1, 2 of spiral- straight guider-cleaner for the conveyor belt is brought together to resultant which is directed in a line of longitudinal axis of the belt, thus providing to the whole system continual and balanced rectilinear course. This proves its main function as a guider of the conveyor belt.
Concerning that by rotating rubber spiral-straight rolls 1, 2 under the arm 10 of the conveyor belt, where the conveyor belt has rectilinear course, cleaning the belt from deposited material is done very effectively, and contribution of separately installed cleaners is minimized. Function of rolls 1, 2 as a shock absorbers is best shown by installing spiral-straight rolls 1, 2 onto metallic rolls under infusion baskets, where during filling and infusion of material onto the belt, shocks of material are buffered and during functioning belt is soothed across all length.
Fig. 4 shows another embodiment of realization for installing left and right spiral -straight rolls 1 and 2 onto the conveyor 3, similarly to embodiment from Fig. 3. Herein also, left and right thread rolls 1, 2 by their outer ends and through the bearings 8 are rotatory lodged onto the holders 9 which are fixed onto pillar carriers 4'. Rolls 1, 2 are by their internal ends mutually in certain larger distance connected through bearings 8' or in some other known way. As rolls 1 and 2 are mutually placed under the angle, i.e., under inclination in relation to vertical plane of symmetry of the belt and in certain larger distance, then the arm 10 of the belt obtains shape of the letter V with very rounded bottom.
According to the invention, Fig. 5 shows yet another embodiment of realization for placement of thread rolls 1, 2 and 12 on belt conveyor 3. Onto the holders 9 which are fixed onto carriers 4', two rolls 1 and 2 are rotatory lodged under the inclination (Figs. 1 and 2). Between these
two rolls 1, 2 on their internal ends through the bearings 8' is lodged horizontally placed roll 12. Roll 12 is made as a roll only with mutually parallel protruding profiles-rings 1"' or 2'". Onto these three rolls 1, 2, and 12 as on a set of spiral-straight guider-cleaner is leaned lower return arm 10 of the conveyor belt. As middle roll 12 is placed horizontally, and left and right rolls 1, 2 are placed under certain inclination, then arm 10 of the belt obtains grooved profile with connections between the sides having a larger radius. In this embodiment also, left and right spiral-straight rolls 1, 2 are by their outer ends and through the bearings 8 rotatory lodged onto holders 9, while by their internal ends rolls are mutually in a distance connected through the bearings 8' or in some other of known ways.
Depending on construction of belt conveyor 3, i.e., depending on width of the belt of the conveyor, combinations of segments i.e., rolls of different lengths are possible. In this way, optimal length of guider-cleaner is obtained and which is in the function of width of the belt of the conveyor. Thus, Fig. 6 shows one embodiment of spiral roll 11 in the case of a straight- line guided conveyor belts in a return run. Roll 11 is comprised of left and right thread roll 1 and 2, i.e., of metallic cylinders 1', 2' which on their outer surface have rubber spirals 1" and 2", Le., rings 1'" or 2'" between the spirals 1" and 2". Spirals 1" and 2", i.e., rings 1'" and 2'", are mutually axially and frontally fixed by hot and cold vulcanization, by which is provided continual course for the roll 11. Horizontally placed roll 11 is rotatory lodged on pillar carriers 4', i.e., holders 9, and through the bearings 8. Onto the roll 11 is in a straight- line leaned lower return arm 10 of the belt.
Way of functioning of the rolls 1, 2, 11 and 12 which can, by different embodiments of realization, be installed on the belt conveyor 3, is simple and it is obvious from the previous description and drawings, so there is no need for further detailed description. According to any of embodiments of realization for installing rolls 1, 2, 11 and 12 as a set with rubber guider, it is clear that this set obtains drive from conveyor belt itself, so for its functioning there is no need for mounting separate driving group with electromotor and reductor. It is important that with proper mounting, rubber rolls 1, 2, 11, 12 by their whole lengths abut to the arm 10 of the conveyor belt, i.e., conveyor belt pushes the same. Intensity of the pressure of the belt onto the rolls is in function of weight and adhesiveness of materials which are transported. Balance of effects of all forces during moving of the belt (tensile, lateral,
centrifugal, vertical forces, etc.) provides rectilinear course of the belt, while by rotating around its axis, working contact surface of spiral rolls efficaciously cleans adhesive material from the belt along whole width without damaging the conveyor belt. Namely, left thread rubber roll 1 and right thread rubber roll 2 produce axial forces which correspond to line and direction of tensile force of the belt, while lateral forces are cancelled as they have same line, but opposite directions.
Way of industrial and other uses of the invention
Way of use of the invention is obvious from the previous specification, and for successful use of present invention there is no need for some special skills, instructions or experience. Ordinarily qualified person in the art is enough skilled for successful use of present invention and according to given description. All functional and ecologic characteristics of the invention have been multiple times checked in a prototype.
Certainly, with keeping the essence of the invention, construction details, technologic preparations and embodiments of realization may be changed in a wide ranges in relation to described and illustrated ones, and without departing from the scope of the present invention.