保定市托辊厂

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：

According to the technical quality level of the idler and the use environment, the reasons for the damage of the idler are mainly as follows:

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 roller is poor, the bearing is dripping water or dust pollution: in order to minimize the rotary resistance of the roller, it is basically a labyrinth seal structure. At present, all the labyrinth sealing structures at home and abroad are designed by the head of the head. Without the basis of the principle, they can not prevent the contamination of the water and dust. As we all know, when the gap of labyrinth seal is large, the sealing effect is not good. Therefore, people racked their brains to minimize the design of the labyrinth seal, the depth of each other, the number of layers (or the number of channels), or the circular arc, so as to achieve an ideal sealing effect. Labyrinth seal clearance is small, can only slow down the speed of water and dust pollution, far from achieving the desired results. Moreover, the grease filled in the labyrinth seal cavity has greatly increased the rotation resistance of the idler.

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 idlers at home and abroad will not last longer than 10 thousand hours in the harsh environment such as water or dust, and the shortest is only 2000.

小时左右，轴承被污染失效的周期根本无法预期。

About half an hour, the cycle of bearing contamination failure can not be expected at all.

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 rotation resistance increases, the circumference of the pipe is quickly penetrated.

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 the chemical reaction gas in the tube is placed in the tube, which makes the pressure of the roller tube larger than the pressure of the outside air to prevent the contaminants from entering the labyrinth seal, so that it can not be done for a long time. There is only one solution: we must ensure that bearings are never contaminated. In 2003, we discovered the principle of sprinkling water or dust entering labyrinth seal during the research and development process. This is also a new discovery of mankind. According to this principle, the labyrinth sealing structure of the water and dust can never be passed through the most outside first seal, so that the bearing can run in a good lubrication state for a long time and reach the 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, the pollution of the mud contaminants to the idlers: when the underground water is large, the coal slurry adhered to the adhesive tape falls to the support and the roller shaft of the two end face of the idler. First fall down and harden and pile up until the end of the idler.

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 falling slime is the height difference between the labyrinth seal cavity. Under the action of pressure difference, the coal slurry can easily enter the labyrinth seal to pollute the bearings. The solution is simple and ingenious: to make a protruding "cleaner" on the rotating seal cover, it has no effect on the resistance of the roller, and can remove the falling mud in time, and prevent the mud from stacking on the end of the roller.

不产生压力差，从而达到稀泥不进入密封的效果。

No pressure difference is generated, so as to achieve the effect that the mud is not sealed.

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. The bearing position of the bearing at both ends of the bearing is different from the axis degree, and the bearing is rotated and early damaged. Because of the accumulative error and welding deformation of the machine, the different axis of the bearing position of the two ends of the roller is beyond the allowable precision range of the bearing, which not only increases the rotation resistance of the roller, but also accelerates the wear between the tube and the tape. To consume electric power, the life of bearing will also be discounted (in the condition of good lubrication, rotary resistance 1N roller, bearing service life of 150 thousand hours; rotation resistance 3N support roller, bearing service life 50 thousand hours; rotation resistance 5 - 8N roller, bearing service life less than 10 thousand hours). The solution is to improve the production technology of idlers so that the rotation resistance of idlers is less than 1N. Our company has developed a successful roll pipe body without a large interference assembly process. It avoids the error caused by the process of mechanical processing or welding deformation, and ensures the different axial degrees of the bearing position of the two 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 0.05mm, the rotation resistance is less than 1N on average, so as to ensure the service life of the bearing reaches 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 the material to the roller tube body: in the iron and steel industry, the coking plant, the sintering or pellet factory, the steel slag and the wet slag, the hard and sharp materials are attached to the tape, and the wear of the pipe body of the roller is very fast.

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；济南钢厂输送钢渣的皮带机，1个多

For example, in the Shanxi Lu Bao coking plant in Shanxi, the parallel underroller is worn off for 10 - 15 days. On the Baoshan Iron and steel mill, the rubber surface of the roller in parallel is worn out in 3 months, and the belt conveyer of the steel slag in the Ji'nan steel plant is more than 1.

月管体就被磨漏；广西来宾B电厂输送炉渣的皮带机托辊，寿命不超3个月，不胜枚举。解决方法是在保证托辊转动灵活度和密封性能的前提下，提高管体的耐磨性能。我们公司目前有两种方法：1、包裹汽车轮胎橡胶耐磨层托辊，改变了尖锐物料与金属钢管的摩擦磨损机理，耐磨性提高20—30倍。例如在焦化厂 15天托辊被磨断的位置，包裹汽车轮胎橡胶耐磨层托辊的使用寿命可达到2年以上；2、模压成型的超高分子量聚乙烯托辊，该托辊的耐磨性仅次于汽车轮胎橡胶，另具有重量轻、无噪音、耐腐蚀锈蚀、省电、不伤胶带、安装方便，降低劳动强度等显著的特点。 

The moon tube body has been worn out; the conveyor belt idler for transporting slag from Guangxi B power plant does not exceed 3 months. The solution is to improve the wear resistance of the tube under the premise of ensuring the flexibility and sealing performance of the idler. There are two methods in our company: 1. The rubber tire rubber wear-resistant roller is wrapped. The friction and wear mechanism of the sharp material and the metal pipe is changed, and the wear resistance is increased by 20 to 30 times. For example, the service life of the automobile tire rubber wear-resistant layer supporting roller can reach more than 2 years in the position of the 15 day roller of the coking plant, and the service life of the rubber wear-resistant layer roller can reach more than 2 years. 2, the molding of the ultra-high molecular weight polyethylene roller, the wear resistance of the roller is second only to the automobile tire rubber, and it has light weight, no noise, corrosion corrosion, electricity saving and no injury. The adhesive tape is easy to install and reduce labor intensity.  

五、托辊管体的严重腐蚀：煤对托辊和胶带的磨损很小。但是在煤矿井下和洗煤厂，钢管托辊管体的损坏，除了转动灵活度差磨损严重外，水中所含的硫对钢管托辊管体产生的腐蚀是相当严重的。含硫小的矿井，灵活转动的钢管托辊，管体厚度4.5毫米，被腐蚀

Five. Serious corrosion of the roller body: the coal wears little to the roller and the adhesive tape. But in the coal mine and coal washing plant, the corrosion of the pipe body caused by the sulfur in the water is very serious, except for the serious wear and tear of the rotational flexibility. Small sulfur mines, flexible steel pipe idlers, 4.5 millimeters thick, corroded.