| Supporting roller is an important component of belt conveyor,which plays a supporting role for conveyor belt and materials.When the idler is damaged,the friction between the conveyor belt and the idler will increase abruptly,resulting in serious wear of the conveyor belt and seriously affecting the transport efficiency of the belt conveyor.In this case,the damaged idler needs to be replaced in time.In order to solve this problem,a belt conveyor idler replacement device is designed according to the size of the belt conveyor.In this paper,the design and research of roller fault and replacement technology are as follows.(1)Three-dimensional modeling of belt conveyor idler replacement device: based on the established three-dimensional model of trough belt conveyor,a belt conveyor idler replacement device is invented and designed.Combined with the three-dimensional model,the working flow of the supporting mechanism was analyzed,and the specific position of the most dangerous working condition was determined by the transient dynamics module of ANSYS.Based on MATLAB software,the workspace of grasping mechanism is simply analyzed,and it is proved that the grasping mechanism can meet the design requirements.(2)To determine the lifting force of the conveyor belt: firstly,the trough conveyor is equivalent to the flat belt conveyor for simulation;Then,the model of lifting flat belt of the support mechanism was established based on Recur Dyn software,and the lifting force curve of flat belt could be obtained.Finally,according to the empirical formula,the lifting force of the flat belt is transformed into the lifting force of the groove belt,and the lifting force of the conveyor belt is determined to check the statics of the support mechanism.(3)Finite element analysis(including statics and modes)was carried out on the support and grasping mechanisms: the results showed that the two most dangerous conditions of the support mechanism met the design requirements,and the most dangerous conditions of the grasping mechanism still met the design requirements;The corresponding frequencies and modes can be obtained by modal analysis of the support mechanism and grasping mechanism under the most dangerous condition.(4)Optimize the design of the support and grasping mechanism: The topology optimization of several parts of the supporting mechanism was carried out,and the redundant parts of the materials were observed.The parametric modeling was carried out based on SOLIDWORKS software,and then the optimal material removal scheme was obtained by size optimization.After optimization,the weight of lifting load-bearing rod A was reduced by 2.814 kg,and the weight of lifting load-bearing beam A was reduced by 11.97 kg.In order to reduce the deformation of the grasping mechanism,a parametric model of the overall association of the grasping mechanism was established based on SOLIDWORKS.The dimensions of multiple parts of the grasping mechanism were analyzed by reference response surface analysis and the design variables were determined.Finally,the dimensions of the grasping mechanism were optimized with seven variables,and the optimized stress was reduced by 16.305 MPa.The deformation is reduced by2.594 mm.There are 91 figures,16 tables and 62 references in this paper. |
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