WO2009095524A1

WO2009095524A1 - A drawing drum or a tilting drum of a belt conveyor

Info

Publication number: WO2009095524A1
Application number: PCT/FI2008/050029
Authority: WO
Inventors: Harri Katajisto; Riina LAHTOMÄKI; Esa Hiltunen; Jari Vatka
Original assignee: Metso Minerals Inc.
Priority date: 2008-01-30
Filing date: 2008-01-30
Publication date: 2009-08-06
Also published as: CL2009000179A1

Abstract

A drawing drum or a tilting drum (1, 1') for a belt conveyor, comprising at least a shaft (2), a shell (3), a first end (4), a second end (5), and an intermediate flange (6). In addition, the first end (4), the second end (5) and the intermediate flange (6) are made at least partly of polymer composite. The invention also relates to a belt conveyor, a crushing plant, a method for forming a drawing or tilting drum for a belt conveyor, as well as the use of polymer composite in a drawing or tilting drum for a belt conveyor.

Description

A DRAWING DRUM OR A TILTING DRUM OF A BELT CONVEYOR

Field of the invention

The invention relates to belt conveyors, particularly belt conveyors used in crushing plants. More precisely, the invention relates to a drawing drum or a tilting drum and a method for manufacturing a drum, as well as a belt conveyor and a crushing plant.

Background of the invention

In crushing plants, belt conveyors are used for transferring material to be crushed and/or crushed material, such as rock, from one place to another. The belt conveyor consists of a conveyor belt loop fitted to run on rollers and/or sliding surfaces fixed to the frame of the conveyor. The movement of the conveyor belt loop is produced by a drawing drum (a drive roll, a capstan) engaging the belt by means of a suitable surface structure. Typically, the surface structure is a friction surface and/or a grooved surface. The drawing drum, in turn, is rotated by means of a suitable actuator, such as a hydraulic motor, an electric motor, or another motor.

At present, the drawing drum is made of steel. The drawing drum consists of a shaft, three flanges and a shell part, which are connected to each other by welding. A hydraulic motor is mounted to one of the end flanges. For the mounting of the motor, the flange is provided with the necessary machinings. To keep the conveyor belt centrally on the drawing drum, the drawing drum must be crowned by machining. The drawing drum is coated with rubber to provide a sufficient friction.

When the drawing drum is made of steel, its mass becomes heavy. Thus, its manipulation is, difficult. Furthermore, the drum at the end of the conveyor causes loads on the structures of the conveyor. Therefore, the frame structures must be dimensioned for the heavy drawing drum, wherein both weight and costs are caused by the surrounding structures. The manufacture of the drum involves several work stages (flame cutting, welding, machining) which raise the costs and make the manufacture slow. Brief Summary of the invention

It is an aim of the solution according to the invention to eliminate drawbacks and faults of the above-presented solutions of prior art.

To achieve this aim, the drawing drum or tilting drum according to the invention is primarily characterized in what will be presented in the independent claim 1. The method according to the invention is, in turn, primarily charac- terized in what will be presented in the independent claim 5. The belt conveyor according to the invention is primarily characterized in what will be presented in the independent claim 9. The crushing plant according to the invention is primarily characterized in what will be presented in the independent claim 13. The use according to the invention is, in turn, primarily charac- terized in what will be presented in the independent claim 17. The other, dependent claims will present some preferred embodiments of the invention.

The basic idea of the invention is that the drum is made primarily of polymeric material, preferably a polymer composite.

The drum according to the invention comprises at least a shaft, a shell, a first and a second end, and at least one intermediate flange, which ends and intermediate flanges extend preferably at least partly in a plane that is transverse to the axial line. In addition, the first end, the second end, and/or the intermediate flange are formed at least partly of a polymer composite, which will be referred to by the term reinforced plastic below.

In one embodiment, filler material, which is cellular plastic, for example poly- urethane, is provided between the ends and the intermediate flanges.

In one embodiment, the flange is made at least partly of a polymer composite.

In another embodiment, the shaft comprises a first shaft part and a second shaft part. The first shaft part is made of a polymer composite. The second shaft part is made of steel. The different embodiments of the above-described solution, taken separately and in various combinations, provide different advantages.

A drawing drum made of reinforced plastic is considerably lighter in weight than one made of steel. In one solution, steel is, for the most part, replaced with fibre reinforcements and with resin that binds them together. The saving in weight is greater than 50% when compared with a conventional structure.

A drawing drum made of reinforced plastic can be manufactured faster. In an advantageous manufacturing method, the blank for a drum does not need to be moved during the manufacture.

In a solution according to one embodiment of the invention, the required dimensional accuracy is achieved directly, wherein no machining is needed.

In one embodiment, the crowning can be provided by using cellular plastic discs with a larger diameter in the central parts of the drum than at the ends of the drum. In another embodiment, in turn, the crowning is provided by coiling more fibre layers in the locations where a larger drum diameter is desired.

Advantageously, a drum made of reinforced plastic is fully interchangeable with a corresponding steel drum, and in serial production, its price is estimated to be less than a half of the price of a steel drum.

Description of the drawings

In the following, the invention will be described in more detail with reference to the appended principle drawings, in which

Fig. 1 shows an advantageous embodiment of a drum,

Fig. 2 shows another embodiment of a drum,

Fig. 3 shows an embodiment of a belt conveyor, Fig. 4 shows an embodiment of a crushing plant.

For the sake of clarity, the drawings only show the details necessary for understanding the invention. The structures and details that are not neces- sary for understanding the invention but are obvious for anyone skilled in the art have been omitted from the figures in order to emphasize the characteristics of the invention.

Detailed description of the invention

Figure 1 is a cross-sectional view of a drum 1 for a belt conveyor, for example a drawing drum or a tilting drum. The drum 1 comprises at least a shaft 2, a shell 3, a first end 4, a second end 5, and intermediate flanges 6. The ends 4, 5 and the intermediate flanges 6 are in a plane that is transverse to the axial line X. The intermediate flanges 6 are also between the first end 4 and the second end 5.

The shaft 2 on the axial line X consists, in the example, of a first shaft part 2a and a second shaft part 2b. The first shaft part 2a is a tube or a bar made of polymeric material, such as reinforced plastic. The second shaft part 2b, in turn, consists of steel in the example. The first shaft part 2a is connected to the second shaft part 2b in a suitable way. Furthermore, in the example, the second end 5 is reinforced with a steel flange 7. Applying the steel parts is an inexpensive way to achieve the strength sufficient for the use. In these con- structions, it is also possible to apply other materials and/or structures, such as composite structures, if they provide a strength that is sufficient for the use. Preferably, the second shaft part 2b and the flange 7 are made of steel or another material with corresponding properties.

The drum shown in Fig. 1 comprises a first end 4 and a second end 5 which are integrated with the shell 3. The intermediate flanges 6 and the filler material layers 8 as well as a part of the first shaft part 2a are inside the drum 1. The second shaft part 2b and the flange 7, in turn, are at the ends of the drum 1. Now turning to Fig. 2, it shows a structure in which the first end 4 consists of a first end flange and the second end 5 consists of a second end flange. Also in this construction, the intermediate flanges 6 and the filler material layers 8 as well as a part of the first shaft part 2a are inside the drum 1. The second shaft part 2b and the flange 7, in turn, are at the ends of the drum 1.

In the examples above, the first end (end flange) 4, the second end (end flange) 5 and the intermediate flange 6 are made at least partly of a polymeric material, such as reinforced plastic. In this context, reinforced plastic refers to a polymer composite consisting of plastic and a reinforcement. Preferably, there are two or more intermediate flanges 6. The number of the intermediate flanges and their placement on the shaft, with respect to each other and the ends of the drum, depend on the length and the diameter of the drum. (In the example, the number of intermediate flanges 6 is seven.) In an advantageous embodiment, the shell 3 surrounding the intermediate flanges 6 of the drum is also made of reinforced plastic.

Filler material 8, preferably cellular plastic, such as polyurethane foam (PUR foam) is provided between the ends 4, 5 and the intermediate flanges 6. The filler material 8 forms a filler material layer that makes the structure of the drum 1 sturdier. Cellular plastics refer to plastics, of which porous materials are made in a controlled manner. Cellular plastics include, for example, PUR, PVC (polyvinyl chloride), PS (polystyrene), PP, PE, and polyolefins.

The drum 1 can be made of the above-mentioned parts by several different methods. The drum 1 shown in Fig. 1 can be made by coiling fibre material around the shaft 2 and the flanges 6 and the filler material layer 8 via the end areas of the drum, wherein the ends 4, 5 and the flange 3 are formed. Preferably, the second shaft part 2b and the flange 7 are connected firmly to the rest of the structure of the drum 1 during the coiling of the fibre material.

In one method, the drum 1 shown in Fig. 2 is formed by composing layers of flanges 4, 5, 6 and filler material layers 8 around a pipe used as the first shaft part 2a. The first end flange 4 and the second end flange 5 are formed at the ends of the drum 1. Between the end flanges 4, 5, in turn, intermediate flanges 6 and filler material layers 8 are fitted in an alternating manner. The second shaft part 2b, made of steel, is fitted at the end of the drum 1 , on the side of the first end flange 4. A steel flange 7 is fitted at the other end of the drum 1 , on the side of the second end flange 5, and connected to the polymer part of the second end flange.

The ends and the flanges 4, 5, 6 are coated with a shell 3 of polymer material, preferably reinforced plastic, for example by forming layers of a reinforcing material and resin. In an advantageous method, the shell 3 is formed by coiling fibres onto the surface of the drum 1. In the coiling, the fibre bundles are first led into a resin bath and from there onto the surface of the rotating drum 1. The coiling angle is changed in such a way that the resin bath moves back and forth in parallel with the drum 1. The number of the fibre bundles to be coiled is used to adjust the width and pitch of the band to be suitable. After the desired number of fibre layers has been coiled around the drum 1 , the resin is left to cure at normal room temperature or in a heating cylinder.

Another advantageous way of forming the drum is to use so-called dry reinforcements. A reinforcement mat is used to form the shell 3 and the ends 4, 5 (or alternatively the shell 3, if end flanges 4, 5 are used) around the shaft 2 and the flanges 6 and the filler material layers 8. After this, for example resin is added to the reinforcement mat by means of negative pressure. Preferably, this is done in so-called vacuum bags.

In addition, the surface of the shell 3 can be provided with a friction structure, if necessary. For example, the surface of the shell 3 can be rubberized. In one embodiment, wear resistant resin is applied for the coating to provide the desired friction between the conveyor belt 9 (shown in Figs. 2 and 3) and the drum 1. Also, the shape of the drum 1 and/or the shell 3 can be utilized to affect the properties between the conveyor belt 9 and the drum 1. For example, the surface of the shell 1 can be provided with grooves and/or the drum can be crowned. The crowning is preferably produced by using flanges

6 and filler material layers 8 with a larger diameter in ^pthe central parts of the drum than at the ends of the drum. In another embodiment, in turn, the crowning is provided by coiling more fibre layers in the locations where a larger drum diameter is desired. In another method, an assembly of the first shaft part 2a and the ends 4, 5 and the intermediate flanges 6 is formed first. The assembly can be formed of different parts or it can formed of a single part, for example by casting. After this, the spaces between the ends 4, 5 and the flanges 6 are filled with filler material 8 and, if necessary, the surfaces of the flanges and the filler material layers are levelled out. The second shaft part 2b and a possible steel flange 7 are also attached to the blank. After this, the shell 3 is formed, for example, by any of the above-described methods.

Figure 3 shows an embodiment of a belt conveyor. The belt conveyor comprises a conveyor belt 9, a drawing drum 1 and a tilting drum 1 ', as well as an idler roll assembly 10 and a return roll assembly 11. The drawing drum and/or tilting drum 1 , 1' comprise at least a shaft 2, a shell 3, a first end 4, a second end 5, and at least one intermediate flange 6, which ends and flanges extend in a plane that is at least partly transverse to the axial line X. According to the example presented above, the first end 4, the second end 5 and the intermediate flange 6 consist at least partly of polymer composite.

Figure 4 shows a crushing plant 100 which is applicable for the processing of mineral material, such as for the crushing of rock or the recirculation of construction material, for example for the processing of reinforced concrete. The crushing plant comprises a feeder 110 for feeding material to be crushed further to a screen 120, and to a crusher 130, such as a cone, gyratory, jaw, or centrifugal crusher. The crushing plant further comprises a side conveyor 140 and a main conveyor 150 as well as a power source 160 for driving the actuators, and a caterpillar drive 170 for moving the crushing plant.

The main and side conveyors of the crushing plant are belt conveyors whose ends at the side of the crushing plant comprise the above-described drawing drum 1 (not shown in the figure), and the opposite ends of the belt conveyors comprise the tilting drum 1 ', 2', the drawing and tilting drums being formed at least partly of polymer composite. The locations of the drawing and tilting drums may also be reversed to those presented above. In the example, the crushing plant is a movable plant with a crusher mounted on a caterpillar drive. The crushing plant can also be moved by other means, such as wheels or legs, or it may be stationary.

In an embodiment illustrating the invention, reinforced plastic refers to a polymer composite consisting of a plastic matrix, such as epoxy, and reinforcement, such as glass fibre. Other resins can also be used as the matrix material, for example vinyl ester or polyester. It is also possible to use other fibre materials, for example carbon or aramid fibres, as the reinforcement.

By combining, in various ways, the methods and structures disclosed in connection with the different embodiments of the invention presented above, it is possible to produce various embodiments of the invention in accordance with the spirit of the invention. Therefore, the above-presented examples must not be interpreted as restrictive to the invention, but the embodiments of the invention may be freely varied within the scope of the inventive features presented in the claims hereinbelow.

Claims

Claims:

1. A drawing drum or a tilting drum for a belt conveyor, comprising at least a shaft with an axial line, - a shell, a first end, a second end, at least one intermediate flange which is between the first end and the second end, characterized in that at least one of the following: the first end, the second end and the intermediate flange, is made at least partly of polymer composite.

2. The drum according to claim 1 , characterized in that filler material, which is cellular plastic, is provided between the ends and the intermediate flanges.

3. The drum according to claim 1 or 2, characterized in that the shell is made at least partly of polymer composite.

4. The drum according to any of the preceding claims, characterized in that the shaft comprises a first shaft part made of polymer composite, and a second shaft part made of steel.

5. A method for forming a drawing drum or a tilting drum for a belt conveyor, which drum is made of a shaft with an axial line, a shell, a first end, - a second end, at least one intermediate flange which is between the first end and the second end, characterized in that at least one of the following: the first end, the second end and the intermediate flange, is made at least partly of polymer compos- ite.

6. The method according to claim 5, characterized in that filler material, which is cellular plastic, is fitted between the ends and the intermediate flanges.

7. The method according to any of the preceding claims 5 or 6, characterized in that the shell is made at least partly of polymer composite.

8. The method according to any of the preceding claims 5 to 7, characterized in that the shaft is formed of - a first shaft part made of polymer composite, and a second shaft part made of steel.

9. A belt conveyor comprising a conveyor belt, a drawing drum and a tilting drum, in which the drawing or tilting drum comprises at least - a shaft with an axial line, .' • a shell, • a first end, a second end, an intermediate flange which is between the first end and the second end, characterized in that at least one of the following: the first end, the second end and the intermediate flange, is made at least partly of polymer composite.

10. The belt conveyor according to claim 9, characterized in that filler material, which is cellular plastic, is provided between the ends and the intermediate flanges.

11. The belt conveyor according to any of the preceding claims 9 or 10, characterized in that the shell is made at least partly of polymer composite.

12. The belt conveyor according to any of the preceding claims 9 to 11 , characterized in that the shaft comprises a first shaft part made of polymer composite, and - a second shaft part made of steel.

13. A crushing plant comprising at least one conveyor, which further comprises a conveyor belt, a drawing drum and a tilting drum, in which the drawing or tilting drum comprises at least a shaft with an axial line, - a shell, a first end, a second end, an intermediate flange which is between the first end and the second end, characterized in that at least one of the following: the first end, the second end and the intermediate flange, is made at least partly of polymer composite.

14. The crushing plant according to claim 13, characterized in that filler material, which is cellular plastic, is provided between the ends and the intermediate flanges.

15. The crushing plant according to any of the preceding claims 13 or 14, characterized in that the shell is made at least partly of polymer composite.

16. The crushing plant according to any of the preceding claims 13 to 15, characterized in that the shaft comprises a first shaft part made of polymer composite, and a second shaft part made of steel.

17. The use of polymer composite in a drawing drum or a tilting drum for a belt conveyor, the drum comprising at least a shaft with an axial line, a shell, - a first end, a second end, an intermediate flange which is between the first end and the second end, characterized in that polymer composite is used at least partly in at least one of the following: the first end, the second end, and the intermediate flange.

18. The use according to claim 17, characterized in that polymer composite is used at least partly in the shell.