| 托辊分类及损坏的原因 |
| 添加时间：2018/1/16 17:20:47 浏览次数： |
| 托辊的分类 Classification of roller 分有各类槽形托辊组，各类平行托辊组，各类调心托辊组，各类缓冲托辊组。按材质分为橡胶托辊、陶瓷托辊、尼龙托辊及绝缘托辊。其尺寸均能满足TD75型胶带机安装要求，特殊情况尺寸可注明订购。 There are various types of grooved roller groups, all kinds of parallel roller groups, various types of heart control rollers, and various types of cushioning roller groups. According to the material, it is divided into rubber roller, ceramic roller, nylon roller and insulation roller. Its size can meet the installation requirements of TD75 type belt conveyor. The size of the special case can be marked for order. 槽形托辊有普通型托辊、前倾型托辊、快换轴承型托辊、吊挂型托辊、三链托辊、可逆托辊、变槽角型托辊、过渡型托辊、V型托辊等；平行托辊有普通型托辊、梳型托辊、前倾型托辊、钢胶托辊型、螺旋型托辊等；调心托辊有通用型、摩擦可逆型托辊、强力型托辊、锥托辊、螺旋型托辊、组合型托辊等；缓冲托辊有弹簧板型托辊、缓冲圈型托辊、强力缓冲型托辊、可调弹力型托辊、吊挂型托辊等。各类辊子的结构先进，性能可靠，辊皮用材经严格挑选，采用优质专用焊管，有严格公差要求。轴材料采用冷拔圆钢，轴承座采用优质钢板冲压，密封结构采用PDC型，三道密封装置，防尘、防水性能均优于国家相关标准。 Trough rollers are common roller, procline roller, quick change type bearing roller, hanging type roller, three chain roller, roller, reversible variable groove angle type roller, transitional roller, V roller; parallel rollers are common roller, comb type roller, procline roller, steel roller type, spiral type rubber roller; self-aligning roller are universal, friction reversible roller, strong type roller, cone roller, roller screw type and combination type roller; buffer roller roller, spring plate buffer ring type roller, strong buffering type roller, adjustable elastic type roller, hanging type roller etc.. All kinds of roller have advanced structure, reliable performance, strict selection of roller skin materials, high quality special welding pipe, and strict tolerance requirements. The shaft material is cold drawn round steel, and the bearing seat is made of high quality steel sheet. The sealing structure adopts PDC type and three seals. The dust-proof and waterproof performance is better than the national standard. 托辊损坏的原因 The cause of the damage of the roller 从托辊的技术质量水平结合使用环境来讲，造成托辊损坏的原因主要有以下几个方面： In terms of the technical quality of the roller and the use of the environment, the causes of the damage of the roller are mainly in the following aspects: 一、托辊的密封性能差，轴承被淋水或粉尘污染：为了尽量减小托辊的旋转阻力，基本上都是采用迷宫式密封结构。目前，国内外所有的迷宫式密封结构，都是拍脑门设计出来的，没有原理的根据，都不能阻止淋水和粉尘对轴承的污染。众所周知，迷宫式密封的间隙大时，密封的效果不好。因此，人们绞尽脑汁，尽可能将迷宫式密封的间隙设计的很小、相互嵌入的深、层数（或道数）多，或者是圆弧形等，以期达到理想的密封效果，岂不知，这是很大的一个误区。迷宫式密封的间隙小，只能有所减缓淋水和粉尘的污染速度，远不能达到理想的效果。并且，迷宫式密封腔内填充的润滑脂，又大幅度增加了托辊的旋转阻力。 First, the sealing performance of the idler is poor, and the bearing is drenched or polluted by dust. In order to minimize the rotation resistance of the idler, the labyrinth seal structure is basically used. At present, domestic and foreign all the labyrinth seal structure, are designed to make Naomen, not according to the principle, can prevent water and dust pollution on bearing. As we all know, when the clearance of the labyrinth seal is large, the effect of sealing is not good. Therefore, people are racking their brains, trying to make the labyrinth seal gap design very small, deep embedded layers or numbers, or circular arcs, so as to achieve the ideal sealing effect. The clearance of the labyrinth seal is small, and it can only slow down the pollution speed of the water and dust, and can not achieve the ideal effect. In addition, the grease filled in the labyrinth seal cavity increases the rotating resistance of the roller. 因此，国内外所有的托辊，在淋水或粉尘等恶劣环境中，使用寿命最长不超过1万小时，最短的只有2000 Therefore, all the domestic and foreign roller, in the drenched water or dust and other harsh environment, the longest service life of no more than 10 thousand hours, the shortest only 2000 小时左右，轴承被污染失效的周期根本无法预期。 During the hour or so, the cycle of the bearing is not expected to be contaminated. 损坏现象有两种： There are two kinds of damage: 1、旋转阻力增大后，管体圆周快速被磨透； 1, when the rotating resistance is increased, the circumference of the tube is quickly worn through. 2、轴承卡死管体被磨出一个口子。 2, the bearing card is worn out of the tube. 据悉，国外有在管体中放置化学反应气体，使托辊管体内压力大于外界空气的压力，以阻止污染物进入迷宫式密封，这样是做不到长期效果的。解决方法只有一个：必须保证轴承永远不被污染。2003年，我们在研发过程中，发现了淋水或粉尘进入迷宫式密封的原理，这也是人类的新发现。并根据该原理，设计出淋水和粉尘永远不能通过最外侧第一道密封的迷宫式密封结构，使轴承能够长期在良好的润滑状态下运转，达到10万小时以上的正常使用寿命。 It is reported that there are chemical reaction gases placed in the tube body abroad, so that the pressure inside the roller tube is greater than that of the outside air, so as to prevent contaminants from entering the labyrinth seal. There is only one solution: it is necessary to ensure that the bearing is never polluted. In 2003, in the process of R & D, we found the principle of drenching or dust entering the labyrinth seal, which is also a new discovery of human beings. According to this principle, the water and dust can never be passed through the labyrinth seal structure with the first outer seal, so that the bearing can run in good lubrication condition for a long time, and achieve a normal service life of more than 100 thousand hours. 二、稀泥类污染物对托辊的污染：煤矿井下的水大时，胶带上粘附的煤泥，掉落到托辊两端面的支架和托辊轴上。先掉下来的变硬后堆积起来，直至将托辊的端 Two, mud pollutants on the roller pollution: coal mine water, tape adhesion of slime, falling to the two end of the support roller and roller shaft. When the fall is hardened, it is piled up until the end of the rollers. 面完全封住。继续掉落的煤泥即与迷宫式密封腔形成高度差。在压差的作用下，煤泥很容易进入迷宫式密封污染轴承。解决方法很简单并且很巧妙：在旋转的密封盖上做一个凸起的“清除器”，既对托辊的阻力没有影响，又可以及时将掉落的稀泥清除下来，阻止稀泥在托辊的端面堆积， The surface is completely sealed. The continued falling slime is the height difference between the labyrinth seal cavity. Under the action of pressure difference, the slime is easy to enter the labyrinth sealed polluted bearing. The solution is simple and ingenious in rotating sealing cover to make a "cleaner", raised not only has no effect on the resistance of the roller, and promptly dropped down to remove mud, prevent mud piled up in the face of roller, 不产生压力差，从而达到稀泥不进入密封的效果。 No pressure difference, so as to achieve the sealing effect into the mud. 三、托辊两端轴承位置不同轴度超差，轴承强行旋转而早期损坏：由于机械加工的累计误差和焊接变形，造成托辊两端轴承位置的不同轴度超出了轴承允许的精度范围，不但使托辊的旋转阻力增大，加速管体和胶带之间的磨损，耗费电力，轴承的寿命也会大打折扣（在良好润滑情况下，旋转阻力1N的托辊，轴承使用寿命达到15万小时；旋转阻力3N的托辊，轴承使用寿命5万小时；旋转阻力5—8N的托辊，轴承使用寿命达不到1万小时）。解决方法是：改进托辊生产工艺，使托辊的旋转阻力平均≤1N 。我们公司研制成功的托辊管体不加工大过盈装配工艺，避免了因机械加工或焊接变形过程中产生的误差，保证了托辊两端轴承位置的不同轴度 Three, roller bearings on both ends of different axis position error, bearing force rotation and early damage: because the accumulative error of machining and welding deformation caused by roller bearings on both ends of the position of the different axis beyond the range of precision bearing allowed, not only make the roller revolving resistance increased, accelerating tube wear between the body the tape and consumption of electric power, the bearing life will be greatly reduced (in good lubrication condition, roller rotating resistance 1N bearing life up to 150 thousand hours; the roller, the rotation resistance 3N life is 50 thousand hours; the use of bearing rotating resistance 5 8N roller bearing service life up to 10 thousand hours). The solution is: to improve the roller production process, the rotating resistance roller average less than 1N. The roller pipe body developed by our company does not interfere with the assembly process. It avoids the errors caused by mechanical process or welding distortion, and ensures the different axes of the bearing positions at both ends of the roller. ≤0.05mm，旋转阻力平均≤1N，从而保证轴承的使用寿命达到15万小时。 Less than or equal to 0.05mm, the average rotation resistance of less than 1N, so as to ensure the service life of the bearing up to 150 thousand hours. 四、物料对托辊管体的严重磨损：在钢铁行业的焦化厂、烧结或球团厂、输送钢渣和湿炉渣，胶带上粘附着硬而尖锐的物料，对托辊钢管管体磨损的很快。 Four, the serious wear of material to the roller pipe body: in the coking plant, sintering or pellet plant, transporting steel slag and wet slag, the hard and sharp material adheres on the adhesive tape is fast wearing on the roller pipe. 例如在山西潞宝焦化厂，平行下托辊10—15天就被磨断；宝钢炼铁厂P301皮带机上，平行下托辊的胶面，3个月就被磨完；济南钢厂输送钢 For example in Shanxi Lubao coking plant, parallel to the lower roller 10 - 15 days to be worn; Baosteel P301 belt, rubber surface parallel to the lower roller, 3 months was finished; Ji'nan iron and steel transportation |
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