Replacement roller assembly

A replacement roller support assembly allows repairing of a conveyor roller support system begins with removing at lease one system roller support from the system base. Next a replacement roller support assembly includes an assembly base with an opening and assembly roller support above each opening for each system roller support removed. The replacement roller support assembly is positioned with the opening and the assembly roller support aligned with the location of the removed roller supports of the system. The support assembly is secured to the system base and the roller is attached to the assembly roller support.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates to conveyor belt roller support systems and more specifically to the replacement roller support assembly.

Conveyor belts, for example, in mines rest on a series of idle rollers. The idle rollers in the conveyor belt roller support system are mounted to roller supports which are integral to a base. The bases are mounted on the ground or on frames or rails above the ground. Depending upon the type of conveyor, there may be two V shaped rollers between three supports or a horizontal roller between two to wing rollers between four supports. The roller supports are usually welded to the base.

In the mining industry, it is usually the interior or center roll of supports which are damaged. One of the general practices is to remove the whole conveyor belt roller support system. As one can imagine, in a mine this takes a lot of time and is very difficult. It requires moving a very large and heavy roller support system.

The present replacement roller support assembly allows repairing of a conveyor roller support system in an efficient manner. It begins with removing at lease one system roller support from the system base. Next a replacement roller support assembly includes an assembly base with an opening and assembly roller support above each opening for each system roller support removed. The replacement roller support assembly is positioned with the opening and the assembly roller support aligned with the location of the removed roller supports of the system. The support assembly is secured to the system base and the roller is attached to the assembly roller support.

The assembly base may be V-shaped or a portion of an arch of a circle in cross-section. The assembly base is secured to the system base by a fastener for example through legs of the assembly base or around the two bases.

The assembly base may include a pair of end members joined by a bridge and the end members each include an opening and assembly rollers support. The bridge may have a V-shaped cross section and the end member are also V shaped with parallel legs each extending from the end of the leg of the V. The parallel legs may include apertures receiving a fastener extending across the V. The apertures may be located on a portion of the leg spaced from a portion of the leg which is aligned with the opening. The assembly base may include one opening and assembly roller support centered on the assembly base.

The assembly roller support may include two end walls joined by two side walls. At least one of the end walls includes a recess and a top edge to receive a portion of the roller. A pair of top walls extends from a respective side wall and between the top edges of the end walls. The side walls may be truncated triangles and one of the end walls is inclined at angle to the other end wall. Both end walls may include a recessed and top edge to receive a portion the respective roller.

These and other aspects of the present invention will become apparent from the following detailed description of the invention, when considered in conjunction with accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A first type of conveyor belt roller support system10is illustrated inFIG. 1. It includes a system base12, a pair of outer roller supports14integral therewith. A pair of inner roller supports16are shown removed from their location from the system base12. A first replacement roller support assembly20is shown mounted on the system base12. Idle rollers18extend between the outer supports14and the replacement support assembly20and a center roller18is mounted to the replacement roller support assembly20.

Although the replacement roller support assembly20inFIG. 1is shown for a three-roller system, it can also be used in a two-roller system with appropriate modification as shown inFIGS. 7-9. The location from which the system roller supports are removed is illustrated by the remaining element or welds17illustrated inFIG. 4on the system base12.

The replacement roller support assembly20as illustrated in detail inFIGS. 2-5, includes an assembly base22on the system base12. The assembly base22includes a pair of end portions24joined by a bridging portion26. A pair of assembly roller supports28, are integral to the assembly base22at end portions24.

Although the assembly base22is shown as three separate pieces welded together it may be one single unit made from a single piece of metal and shaped as appropriate. Also on the bridge26can have the shape as the end portions24.

The roller supports28are shown welded at27inFIGS. 3 and 4to end portion24of the assembly base22. The assembly roller support28is positioned above an opening30in the base end portion24. Both are aligned and overlap the position, shown by example the remaining element17, in which the system roller supports16were removed. The opening30allows the base22to lie snuggly on the system base12. If it did not lie snuggly the alignment of the ultimately attached rollers would be skewed.

A slot32in the base end portions24separates the portion34from the main body. The portion34is from the main body which includes the opening30and the assembly roller supports28. The end portion24is shaped to conform to the base12of the support system. In the example shown inFIGS. 1 and 2, the support system base12is V-shaped and consequentially the base22of the assembly is V-shaped. As illustrated inFIG. 3, a pair of parallel legs38extends from the V-shape of the end portion24of the assembly base22.

An aperture36is provided in the legs38to receive a fastener39which extends across the V to tighten and secure the replacement roller support assembly to the system base12. Tightening of the fastener39in combination with the slot32allows the parallel legs36to flex if necessary for further securement. This is especially important because of the vibration set up in the use of the conveyor system. The fastener39is shown as a bolt, but may also be a cotter pin or other simple fastener or clamp.

The structure of roller supports28, of the replacement roller support assembly ofFIGS. 1 and 2, is illustrated in detail inFIG. 3. The assembly support28includes two end walls40and42joined by two side walls46and48. The top edges of the walls are covered by a top50. The front wall40includes a recess52to receive a portion of a roller and the rear wall42also includes a recess54to receive a portion of a roller.

The space between the end walls40and42are greater than the space between the ends walls of the system roller support16to accommodate any portion of the system roller support16remaining. To aid in alignment of the replacement roller support assembly20to the roller support system10, the system roller support16is removed such as to leave a stub extending from the system base12into the openings30in the assembly base22after positioning the support assembly20on the support system10.

In construction, the four walls40,42,46, and48are each individually made and welded together. The top wall50may be an extension of the side wall and bent over prior to welding. As previously discussed the roller support28is welded at27to the end portion24of the assembly support.

As illustrated inFIG. 5, an axle60of the roller18received in recess52in the end wall40.

A second replacement roller support assembly20′ for a second type of conveyor belt roller support system10is illustrated inFIG. 6. the assembly base12′ is an arc. The replacement roller support assembly20′ includes an assembly base22′ which is an arc of a circle in cross-section. The assembly roller support28is positioned above an opening30in the end portions of the assembly base22′. Both are aligned and overlap the position, shown by example the remaining element17, in which the system roller supports16were removed. The remaining element or stub17extends from the system base into the openings in the assembly base after positioning the support assembly. This will limit movement of the assembly base22′ on the system base12′ rotationally and axially.

The assembly base22′ includes apertures36for receiving fasteners39to secure the assembly base22′ on the system base12′. The fastener39is shown as a bolt with washer33, lock washer35, and nut37.

A third replacement roller support assembly20″ for a third type of conveyor belt roller support system10″ is illustrated inFIG. 7. It includes a system base12″ and a pair of outer roller supports14″ integral therewith. An inner roller support16″ is centered on the system base12″. Rollers18, shown in phantom, extend between the outer supports14″ and the inner support16″. In this system, the system base12″ is circular, for example a pipe welded to the side rails.

The replacement roller support assembly20″ includes an assembly base22″ which is an arc of a circle in cross-section. A single assembly roller support28is positioned above an opening30in the center portions of the assembly base22″. Both are aligned and overlap the position, shown by example the remaining element17, in which the system roller support16″ was removed.

The diameter of the arc of the assembly base22″ is larger than the diameter of the arc of the system base12″. For example, the diameter of the arc of the assembly base22″ maybe 11¼ inches and the diameter of the arch of the system base12″ may be 10¾ inches. The remaining element or stub17extends from the system base into the opening30in the assembly base after positioning the support assembly. This will limit movement of the assembly base22″ on the system base12″ rotationally and axially.

The assembly base22″ is secured on the system base12″ by a fastener shown as a U-bolt clamp. A U-bolt70is secured to bracket72by washer74, lock washer76, and nut78. An opening may be provided in the assembly base22″ to receive the clamp or U-bolt70. This would limit any axial movement between the assembly base22″ and the clamp or U-bolt70. Other clamps may be used, for example a ring or band clamp.

A detailed view of the system roller support16″ is shown inFIG. 8Aand the assembly roller support28inFIG. 8B. Those elements having the same function include the same number. The system roller support16′ includes two end walls40″ and42″ joined by two side walls46″ and48″. The top edges of the end walls40″ and42″ are covered or joined by tops50″. The front wall40″ includes a recess52″ to receive a portion of a roller and the rear wall42″ also includes a recess54″ to receive a portion of a roller. The assembly support28includes two end walls40and42joined by two side walls46and48. The top edges of the end walls40and42are covered by tops50. The front wall40includes a recess52to receive a portion of a roller and the rear wall42also includes a recess54to receive a portion of a roller.

Another fastener for the replacement roller support assembly20″ is shown inFIG. 9. A arch of a circle cross-sectional clamp80is secured to the assembly base22″ by fasteners84extending through apertures82in the clamp80and into threaded apertures36in legs38of the assembly base22″.