Design and application of belt lifting mechanism for replacing idler of belt conveyor

doi:10.3785/j.issn.1006-754X.2023.03.127

Chinese Journal of Engineering Design

2023, Vol. 30

Issue (6): 667-677 DOI: 10.3785/j.issn.1006-754X.2023.03.127

Innovative Design

Design and application of belt lifting mechanism for replacing idler of belt conveyor

Liyong TIAN(

),Rui TANG,Ning YU,Hongyue CHEN

School of Mechanical Engineering, Liaoning Technical University, Fuxin 123000, China

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Abstract

Aiming at the problems of the frequent idler failure of long-haul large belt conveyor, idler replacement work leading to shutdown, and the low efficiency and single equipment of traditional manual idler replacement, a robot that can realize non-stop idler replacement is proposed to improve the idler replacement efficiency by taking the belt conveyor in the main adit of Wangjialing Coal Mine as the research object. The belt lifting mechanism is an important part of idler replacement robot. Based on the functional requirements of the robot and the characteristics of narrow space and large belt load of belt conveyors, a scissor-fork belt lifting mechanism was designed. Firstly, the three-dimensional model of the scissor-fork belt lifting mechanism was constructed by SolidWorks software. After the working load of belt lifting was calculated according to the parameters of the belt conveyor, the force analysis for belt lifting mechanism was carried out. Then, the kinematics simulation analysis for belt lifting mechanism was conducted by SolidWorks Motion module and the statics simulation analysis was carried out by ANSYS Workbench finite element software. Finally, the ground test and underground test were carried out to verify the feasibility of the designed belt lifting mechanism. The ground test results showed that under the load of 20?60 kN, the matching accuracy between the measured and simulated vertical displacement of the belt lifting mechanism was 6%?15%, which verified that the bearing capacity of its main structure met the design requirements. The underground test results proved the rationality and reliability of the belt lifting mechanism design. The bearing capacity and lifting height of the scissor-fork belt lifting mechanism meet the functional requirements of the idler replacement robot, which is a key technical breakthrough to realize the non-stop replacement of idlers for belt conveyors.

Key words： belt conveyor non-stop idler replacement belt lifting mechanism simulation analysis

Received: 06 March 2023 Published: 02 January 2024

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Cite this article:

Liyong TIAN,Rui TANG,Ning YU,Hongyue CHEN. Design and application of belt lifting mechanism for replacing idler of belt conveyor. Chinese Journal of Engineering Design, 2023, 30(6): 667-677.

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https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2023.03.127 OR https://www.zjujournals.com/gcsjxb/Y2023/V30/I6/667

带式输送机更换托辊用皮带举升机构设计与应用

针对长运距大型带式输送机托辊故障频发，托辊更换工作导致停机停产，以及传统人工更换托辊方式效率低、设备单一等问题，以王家岭煤矿主平硐带式输送机为研究对象，提出了一种可实现不停机更换托辊的机器人，以提高托辊更换效率。皮带举升机构是更换托辊机器人的重要部件，基于该机器人的功能需求以及带式输送机空间狭窄、皮带载荷大等特点，设计了剪叉式皮带举升机构。首先，利用SolidWorks软件构建了剪叉式皮带举升机构的三维模型，基于带式输送机参数计算得到举升皮带的工作载荷后，对皮带举升机构进行受力分析。然后，采用SolidWorks Motion模块对皮带举升机构进行运动学仿真分析，同时利用ANSYS Workbench有限元软件对其进行静力学仿真分析。最后，开展地面试验和井下试验，以验证所设计的皮带举升机构的可行性。地面试验结果表明，在20~60 kN载荷下，皮带举升机构竖直位移的实测结果与仿真结果的匹配精度为6%~15%，验证了其主体结构的承载能力满足设计要求；井下试验结果证明了皮带举升机构设计的合理性和可靠性。剪叉式皮带举升机构的承载能力和举升高度均符合更换托辊机器人的功能需求，是实现带式输送机不停机更换托辊的关键技术突破。

关键词： 带式输送机, 不停机更换托辊, 皮带举升机构, 仿真分析

Fig.1 Structure composition of idler replacement robot

Fig.2 Structure schematic of belt conveyor

Fig.3 Structure schematic of groove-shape idler group

Fig.4 Three-dimensional model of swing-type belt lifting mechanism

Fig.5 Structure sketch of scissor-fork belt lifting mechanism

Fig.6 Three-dimensional model of scissor-fork belt lifting mechanism

Table 1 Key parameters of belt conveyor

Fig.7 Belt tension force analysis

Fig.8 Schematic diagram of material cross-sectional shape on belt conveyor

Fig.9 Force analysis of idler

Fig.10 Pressure distribution of idler surface

Fig.11 Schematic of lifting status of scissor-fork belt lifting mechanism

Fig.12 Force analysis of scissor arm

Fig.13 Initial and final posture of scissor-fork belt lifting mechanism

Fig.14 Motion curve of lifting cylinder

Fig.15 Vertical displacement curve of intermediate idler frame

Fig.16 Angular velocity and angular acceleration curves of scissor arm

Table 2 Main component materials of scissor-fork belt lifting mechanism

Fig.17 Finite element grid model of scissor-fork belt lifting mechanism

Fig.18 Equivalent stress cloud map of scissor-fork belt lifting mechanism

Fig.19 Deformation cloud map of scissor-fork belt lifting mechanism

Fig.20 Ground test site of belt lifting mechanism

Table 3 Comparison of vertical displacement of intermediate idler frame under different loads

Fig.21 Underground test site in shutdown state

Fig.22 Underground test site under working condition

Fig.23 Belt lifting height measurement site

Fig.24 Variation curve of belt lifting height


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