同步帶及輸送帶設(shè)計(jì)【三維SW】
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目 錄
第1章 總體設(shè)計(jì)要點(diǎn)和設(shè)計(jì)要求 1
1.1設(shè)計(jì)數(shù)據(jù) 1
1.2工作條件及要求 1
第2章 同步帶傳動件的設(shè)計(jì)計(jì)算 2
2.1選擇電動機(jī) 2
2.2計(jì)算各軸轉(zhuǎn)速、功率、轉(zhuǎn)矩 3
2.2.1計(jì)算各軸轉(zhuǎn)速 3
2.2.2計(jì)算各軸功率 3
2.2.3計(jì)算各軸轉(zhuǎn)矩 3
2.3同步帶及同步帶輪的設(shè)計(jì)計(jì)算 3
2.3.1選擇材料 3
2.3.2確定傳動件的主要參數(shù)并計(jì)算幾何尺寸 4
2.4數(shù)據(jù)整理 6
2.5輸送帶的選擇 6
第3章 軸的校核計(jì)算 7
3.1軸的校核 7
第4章 軸承的校核計(jì)算 10
4.1軸承的校核 10
第5章 鍵的選擇和校核 11
5.1選擇鍵連接的類型和尺寸 11
5.2校核鍵的連接強(qiáng)度 11
第6章 總結(jié) 12
參考文獻(xiàn) 13
摘要
帶式輸送機(jī)是現(xiàn)代運(yùn)輸物料設(shè)備中不可缺少的設(shè)備之一，以結(jié)構(gòu)簡單、操作方便、便于維修、動力資源耗損少、運(yùn)行可靠、通用性強(qiáng)等優(yōu)點(diǎn)。隨著科技的發(fā)展，帶式輸送機(jī)也朝著更遠(yuǎn)距離，更高帶速，更大運(yùn)量的方向發(fā)展。但是，對于輕載定比傳動而言，同步帶傳動是最初采用的。隨著強(qiáng)力層所采用材料的發(fā)展，加之對齒形的進(jìn)一步改進(jìn)，現(xiàn)在，同步帶已廣泛應(yīng)用于各種工業(yè)領(lǐng)域的運(yùn)動和動力傳遞。傳動帶傳動與V帶，平帶相比，它具有很多優(yōu)點(diǎn)。如：傳動精確，傳動效率高，傳動大、載動范圍大，傳動速度高，結(jié)構(gòu)緊湊，沖擊小、傳動平穩(wěn)，噪聲小等有點(diǎn)。對于輸送帶來說，輸送帶是輸送系統(tǒng)的關(guān)鍵設(shè)備，它的安全穩(wěn)定運(yùn)行直接影響到生產(chǎn)作業(yè)。輸送帶的跑偏是帶式輸送機(jī)的最常見故障，對其及時(shí)準(zhǔn)確的處理是其安全穩(wěn)定運(yùn)行的保障。不同材質(zhì)的輸送帶有不同的優(yōu)缺點(diǎn)，如：高效性，高承載性，誤差性小，安全性高。在使用的過程中可根據(jù)使用的場合來決定。有時(shí)對于輸送帶使用的過程中要求產(chǎn)生跳動少的情況，可以使用PVG輸送帶，其過滾筒性好。
關(guān)鍵詞 同步帶 輸送帶 滾筒
第1章 總體設(shè)計(jì)要點(diǎn)和設(shè)計(jì)要求
1－調(diào)速電動機(jī) 2－同步帶 3－卷筒 4－輸送帶及機(jī)架
1.1設(shè)計(jì)數(shù)據(jù)
F= 2000 N, V= 1.4 m/s, D= 250 mm。
D
1.2工作條件及要求
1.工作情況：兩班制，連續(xù)單向轉(zhuǎn)動，
載荷平穩(wěn)；
2.工作環(huán)境：室內(nèi)，無灰塵；
3.工作年限：8年，大修期4年；
4.生產(chǎn)批量：小批量生產(chǎn)。
第2章 同步帶傳動件的設(shè)計(jì)計(jì)算
2.1選擇電動機(jī)
1類型和結(jié)構(gòu)的選擇
三相交流異步電動機(jī)的結(jié)構(gòu)簡單、價(jià)格低廉、維護(hù)方便，但一般應(yīng)用于工業(yè)。
Y系列電動機(jī)是一般用途的全封閉式自扇冷式三相異步電動機(jī)，具有效率高、性能好、噪聲低、振動小等優(yōu)點(diǎn)，適用于不易燃、不易爆、無腐蝕性氣體和無特殊要求的機(jī)器上，如風(fēng)機(jī)、輸送機(jī)、攪拌機(jī)、農(nóng)業(yè)機(jī)械和食品機(jī)械等。
選用Y系列電動機(jī)作為帶式輸送機(jī)的電機(jī)。
2功率的確定
電機(jī)的容量選擇是否合適，對電動機(jī)的工作和經(jīng)濟(jì)性都有影響。當(dāng)容量小于工作要求時(shí)，電動機(jī)不能保證工作機(jī)的正常工作，或使電動機(jī)因長時(shí)間過載而過早損壞；若容量過大，則電動機(jī)價(jià)格高，能力不能充分利用，而且因?yàn)榻?jīng)常不在滿載運(yùn)行，其效率和功率因數(shù)較低，造成浪費(fèi)。
故工作機(jī)所需工作效率，查表可知，同步帶的機(jī)械效率為，卷筒的機(jī)械效率為，故總機(jī)械效率為，所需電機(jī)輸出功率。
因?yàn)樗x電動機(jī)的額定功率應(yīng)稍大于（或等于）所需的電動機(jī)功率。
3轉(zhuǎn)速的確定
卷筒為工作軸，則轉(zhuǎn)速，故同步轉(zhuǎn)速為1500r/min。所以查表可知，電動機(jī)型號的選擇為Y100L1-4型，，額定轉(zhuǎn)矩為2.2kw，滿載轉(zhuǎn)速為1420r/min。
2.2計(jì)算各軸轉(zhuǎn)速、功率、轉(zhuǎn)矩
2.2.1計(jì)算各軸轉(zhuǎn)速
主動軸的轉(zhuǎn)速 ，
從動軸的轉(zhuǎn)速；
2.2.2計(jì)算各軸功率
主動軸的功率
從動軸的功率；
2.2.3計(jì)算各軸轉(zhuǎn)矩
主動軸的轉(zhuǎn)矩，
從動軸的轉(zhuǎn)矩。
2.3同步帶及同步帶輪的設(shè)計(jì)計(jì)算
2.3.1選擇材料
同步帶的齒形和材料在整個(gè)發(fā)展過程中出現(xiàn)了很多類型，在本次課設(shè)中，我們所選用的材料為氫化丁橡膠，齒形為梯形。
2.3.2確定傳動件的主要參數(shù)并計(jì)算幾何尺寸
1確定同步帶傳動的設(shè)計(jì)功率
查表可知，載荷修正系數(shù)，故設(shè)計(jì)功率。
2確定帶的型號和節(jié)距
可根據(jù)同步帶傳動的設(shè)計(jì)功率和小帶輪轉(zhuǎn)速n、由同步帶選型圖中來確定所需要采用的帶的型號和節(jié)距。所以帶的型號選用H型，對應(yīng)節(jié)距為。
3選擇帶輪齒數(shù)
有小帶輪轉(zhuǎn)速和H型帶，查表得小帶輪最小許用齒數(shù)，又根據(jù)查表可知，，所以，則大帶輪齒數(shù)。
4確定帶輪節(jié)圓直徑
小帶輪節(jié)圓直徑；
大帶輪節(jié)圓直徑。
5確定帶速
又因?yàn)閹伲詭賤合格。
6初定中心距
所以。
7初定帶的節(jié)線長度及其齒數(shù)
又查表可知，。
8實(shí)際中心距
由于中心距可調(diào)整，所以。
9確定帶寬
由帶長和其齒數(shù)查表可知，帶寬。
10確定小帶輪嚙合齒數(shù)
故，小帶輪嚙合齒數(shù)合格。
11作用在軸上的力
12校核
基準(zhǔn)額定功率
查表可知，許用工作拉力，單位長度質(zhì)量，故：
。
所以，所選參數(shù)合格。
2.4數(shù)據(jù)整理
帶：選用H型號同步帶，齒形為梯形，
帶輪：。
2.5輸送帶的選擇
由于此次設(shè)計(jì)的骨架是整體編制結(jié)構(gòu)，抗撕裂、抗沖擊性能好，易清掃，可滿足長距離輸送機(jī)的設(shè)計(jì)要求，且由于帶體輕，所需的驅(qū)動功率小，又可用于機(jī)械的連接，所以我們的輸送帶選擇橡膠面整芯輸送帶，即PVG帶。
骨架的長為560mm，寬為480mm，高為587mm;輸送帶長為1150mm。
14
第3章 軸的校核計(jì)算
3.1軸的校核
軸的材料選用45鋼，熱處理方式為調(diào)質(zhì)，故查表可知，許用應(yīng)力。
故，彎矩圖和扭轉(zhuǎn)圖如下圖所示：
圖1-1彎矩圖
圖1-2扭矩圖
各段軸的強(qiáng)度校核如下：
A點(diǎn) 軸的抗扭截面系數(shù)，軸的抗彎截面系數(shù)
所以，扭轉(zhuǎn)切應(yīng)力，彎曲應(yīng)力
又根據(jù)第三強(qiáng)度理論校核可知，
，
式中，由扭轉(zhuǎn)切應(yīng)力為對稱循環(huán)變應(yīng)力可知，取。
B點(diǎn) 軸的抗彎截面系數(shù)。
所以，彎曲應(yīng)力。
C點(diǎn) 軸的抗彎截面系數(shù)。
所以，彎曲應(yīng)力。
故，三段軸均滿足強(qiáng)度要求。
第4章 軸承的校核計(jì)算
4.1軸承的校核
考慮軸受力較小且主要是徑向力，故選用深溝球軸承。所以根據(jù)查手冊可選6005四個(gè)，基本額定動載荷。
圓周力即作用在軸上的力；所以兩軸承承受純徑向載荷。
根據(jù)查表可得，，又因?yàn)槭乔蜉S承，所以，故
；
預(yù)期壽命為：8年，兩班制，所以
即，軸承選用合格。
第5章 鍵的選擇和校核
5.1選擇鍵連接的類型和尺寸
選用平鍵鏈接，由于帶輪在軸端，故選用單圓頭普通平鍵（C型）。
由于軸的直徑，所以查表可得，鍵的截面尺寸為：寬度，高度。因?yàn)殒I的長度比輪轂要小，根據(jù)輪轂的長度以及參考鍵的長度系列，取鍵的長度為。
5.2校核鍵的連接強(qiáng)度
鍵的材料為鋼，由表可查，許用擠壓應(yīng)力，取平均值，。鍵的工作長度，所以，
，
所以選用的鍵合適，為：單元頭普通平鍵 鍵C。
第6章 總結(jié)
本次課設(shè)是我們在大學(xué)期間的最后一次課設(shè)，而這一次課設(shè)所需要的知識也比較廣泛，綜合性也較強(qiáng)，也是為我們畢業(yè)設(shè)計(jì)做了一些準(zhǔn)備，提前熟悉一下步驟，培養(yǎng)如何查資料等一些能力。
此次課設(shè)，我們分了幾個(gè)組，每組基本都是4人左右，我們組做的是同步帶與輸送帶方面的設(shè)計(jì)，在此過程中，我們不只局限于設(shè)計(jì)，還有我們的動手能力，我們在一邊設(shè)計(jì)一邊拆裝，能夠更好的了解和認(rèn)識其構(gòu)造及組成。所以這一次課設(shè)，主要培養(yǎng)了我們理論聯(lián)系實(shí)際的設(shè)計(jì)理念，訓(xùn)練綜合運(yùn)用機(jī)械設(shè)計(jì)課程和其他相關(guān)課程的基礎(chǔ)理論并結(jié)合生產(chǎn)實(shí)際進(jìn)行分析和解決工程實(shí)際問題的能力，鞏固、深化和擴(kuò)展了相關(guān)機(jī)械設(shè)計(jì)方面的知識。
當(dāng)然，也提高了我們動手查閱和使用標(biāo)準(zhǔn)、規(guī)范的手冊和圖冊及相關(guān)的技術(shù)資料的能力及計(jì)算、繪圖、數(shù)據(jù)處理等設(shè)計(jì)方面的能力。通過對簡單的機(jī)械設(shè)計(jì)，使我們掌握了一定的機(jī)械設(shè)計(jì)的程序和方法，同時(shí)樹立正確的工程設(shè)計(jì)思想，培養(yǎng)獨(dú)立、全面、科學(xué)的工程設(shè)計(jì)能力和創(chuàng)新能力。更重要的是，這次課設(shè)也為我們即將到來的畢業(yè)設(shè)計(jì)做了準(zhǔn)備，讓我們提前了解了一些步驟及思路。
參考文獻(xiàn)
[1] 盧松峰.機(jī)械設(shè)計(jì)課程設(shè)計(jì)手冊.北京.中央廣播電視大學(xué)出版.1998.7
[2] 陳國立,吳立言.機(jī)械設(shè)計(jì).北京.高等教育出版社.2013.5
[3] 陳鐵鳴.機(jī)械設(shè)計(jì)課程設(shè)計(jì)圖冊.北京.高等教育出版社.2009.4
Procedia Engineering 26 (2011) 942 9461877-7058 2011 Published by Elsevier Ltd.doi:10.1016/j.proeng.2011.11.2260Available online at First International Symposium on Mine Safety Science and EngineeringTypical failure analysis and processing of belt conveyorLihua ZHAOSchool of Mechanical Engineering, Northeast Dianli University, Jilin City, Jilin Province Changchun Road 169,132012,China,Yin LINAbstractThe paper analyzes two typical failure forms of roller and conveyor at the belt conveyor, and describes the maintenance methods of prevention and elimination failures to ensure the normal operation of belt conveyor. 2011 Published by Elsevier Ltd. Selection and/or peer-review under responsibility of China Academy of Safety Science and Technology, China University of Mining and Technology(Beijing), McGill University and University of Wollongong.Keywords: belt conveyor; conveyor deviation;roller; typical failure.1. Introduction Belt conveyor is a commonly used equipment of continuous transport, it has a high efficiency andlarge conveying capacity, simpler construction,small amount of maintenance. Can be achieved at different distances, different materials transportation. It iss widely used in mining, coal handling system in thermal power plant and other projects. Belt conveyor will often occur some typical problems in the course,this paper Based on research common typical failure of belt conveyor during use,analysis the cause offailure,proposed some effective methods to solve the problem.2. Typical faults of conveyor belt2.1. Conveyor belt deviationIn the belt conveyor, as the conveyor belt is traction components, transmit power and motion, also is carrying components, support material load. Working more complex, so at work often happen belt deviation. Deviation is the conveyor belt during operation, the center line of belt deviation the center line of conveyor. As the conveyor belt deviation may cause between the belt edge and rack wear, cause belt Lihua ZHAO. Tel: +0086-432-64822626; fax: +0086-432-64666020. Email: 943Lihua ZHAO and Yin LIN / Procedia Engineering 26 (2011) 942 946edge premature damage, Ranging impact the life of conveyors, affect the throughput of materials, Weight is caused by withdrawal material, even happen stop occurrence, direct impact on production. As the conveyor belt is more important, the most expensive parts. Its price about 25%50% to the conveyor. So analysis the reasons of belt deviation, reduce and eliminate belt deviation, It is an important part of ensure belt to work, extend equipment life. Cause the belt occurs deviation because of the following factors.2.1.1. In the device itselfa. Rack rigid is poor, large deformation under load, causing the belt deviation.b. The larger error of roller outer cylindrical, caused deviation when the conveyor belt running.c. The supporting roller rotation is not flexible, causes the conveyor belt both sides stress to be uneven, causes the conveyor belt deviation.d. The parallelism error cylindrical axis and roller axis is too big, causes the conveyor belt deviation.e. Conveyor belt itself is questionable quality, thin and thick uneven, caused a shock lead running conveyor belt deviation.f. Conveyor belt manufacturing quality have defects, the length of belt both sides edge is inconsistent,cause running conveyor belt deviation.g. Not parallel with belt connector, connection error is too big, cause belt deviation.2.1.2. Installation adjustmenta. Drive, change roller axis and conveyor centerline vertical error is too big, make conveyor and horizontal line have a bigr inclination, cause belt deviation.b. Roller axis and conveyor centerline vertical error is big, will cause belt deviation also.c. The connection strength between rack and ground is not enough, the rack unstable, causing belt deviation.d. The feeding plate of discharge trough and improperly located, both sides of the conveyor belt uneven force cause belt deviation.2.1.3. With maintenancea. The cleaning performance of sweeper is poor, make the roller cylindrical diameter local increases.b. Feeding mouth location is wrong, so that the material partial load on the conveyor belt, cause belt deviation.c. Poor maintenance and improper adjustment, resulting in the conveyor belt deviation.d. For the steel cord belt, as the manufacture of steel cord is uneven force, so that a deviation occurs in the operation, or a strong difference of belt, large elongation under load, causing the vibration, the belt will deviation.e. Also, the vibration of running conveyor belt system can cause the deviation.f. In addition, when conveying some viscous material, make the roller, etc. bonding materials, make the cylindrical diameter of roller part increases, causing belt deviation.2.2. Measures to prevent the belt deviation2.2.1. Due to equipment in the manufacture of conveyor belt causes the deviation, primarily through improved design, manufacture precision to prevent and reduce the occurrence of conveyor belt deviation.2.2.2. For installation adjust improper and daily use causes deviation, mainly the following aspects should be considered:944 Lihua ZHAO and Yin LIN / Procedia Engineering 26 (2011) 942 946Conveyor belt in drive roller or on rear rollers deviation, usually by adjusting the position of the roller bearing ways to eliminate, usually by adjusting the position of the roller bearing ways to eliminate.a.The longitudinal centerline of the roller rotation axis and conveyor is not perpendicular, resulting in the conveyor belt one side loose and the other tight, belt move from the tight side to the loose side, Occurs deviation phenomenon. Should be adjusted bearing position of the tighten deviation side. Make horizontal pull of belt equal, eliminate deviation. When tail roller is spiral tensioning,the reasons of tail deviation may be due to the top tight power of tensioning device both sides screw rod are not equal, resulting in caused by imbalance.b. Cylinder axis is not horizontal, at both ends bearing of the height difference is cause another reason of head or tail deviation. At this point, at both ends roller bearing should add and subtract shims way to leveling roller axis ,to eliminate conveyor belt deviation.c. Roller surface adhesion material, equivalent to increasing the roller local rdiameter, will cause the conveyor belt deviation, should strengthen empty segment cleaning of conveyor belt to reduce the adhesive material or dust accumulation on the conveyor belt. In addition, the conveyor belt between the nose and tail parts deviation, called central or local deviation. Such deviation reasons is more complex, it is with the conveyor belt along device exposure to a relationship. Need a detailed analysis for specific issues. Using the following methods can resolve these issues.A. Load or no-load branch roller axis with the conveyor belt running centerline is not perpendicular, causing tape at the roller deviation. Deviation ends should adjustment to the conveyor belt running direction. At this time often need to adjust the adjacent groups of rollers in order to achieve the purpose of eliminating deviation, adjusting deviation angle should not be too big.B. Conveyor belt joint with the tape centerline (trumpet) is not perpendicular, to cause the deviation, Should improved installation connection accuracy to eliminate deviation.C. If material loaded on the conveyor belt is straight; make the material block and weight distribution along bandwidth direction distribution serious inequality, cause deviation, through adjustment blanking tube and skirt plate location method to be eliminated.D. Recently, it was suggested that the method of application film for transfer partial conveyor belt, because of high manufacturing costs and some technical problems not well solved, makes this method very difficult to promote the use.3. The typical failure of roller3.1. Operation is not flexibleEach belt conveyor have lot number rollers, installation shown in Picture 1, their work status directly affects the conveyor is working. According to the actual work of conveyor, roller in the conveyor system can be classified four kinds according their efect, trough roller, parallel roller, buffer roller and self-aligning roller; according to the loads case can be divided two kinds, no-load roller and bearing roller. Trough roller use bearing branches of materials, play a supporting role and increased throughput role.Parallel roller is a long-shaped roller, for no-load branch of conveyor, to play a supporting role of no-load branch tape; buffer roller is trough roller too. Flexible support trough roller be installed on conveyor load branch, Installed in the material office. Reduce the impact of material for conveyor belt, protect the tape and support bearing. Generally based on the elastic support were divided into rubber ring and spring plate; the role of self-aligning roller is a certain degree of automatic adjustment of conveyor belt deviation, To avoid excessive wear of belt and materials scattered. In the load and no-load branch are equipped with a number of self-aligning roller. The self-aligning principle shown in Fig. 2.945Lihua ZHAO and Yin LIN / Procedia Engineering 26 (2011) 942 946Roller bearingGoods Vtape movement Direction belt belt Spherical roller ax OFig.1. Installs the schematic drawing Fig. 2. Adjusts the heart principleManufacture installation quality of roller directly affect the life and running resistance of conveyor belt. roller repair and replacement costs are also an important part of conveyor belt operating expenses. The roller operation quality for conveyor of the running resistance, power consumption, roller and belt life, maintenance workload and cost of transportation has a significant impact. Therefore, analysis method to extend the service life of rollers, also an important contents to ensure stable operation of belt conveyor, practical significance in engineering. Trough roller of belt conveyor systems used on material bearing branch, play supporting role and increased throughput role. Parallel roller is a long-shaped roller, for no-load branch of conveyor, to play a supporting role of no-load branch tape; buffer roller is trough roller too. Flexible support trough roller be installed on conveyor load branch, Installed in the material office. Reduce the impact of material for conveyor belt, protect the tape and support bearing. The role of self-aligning roller is a certain degree of automatic adjustment of conveyor belt deviation, To avoid excessive wear of belt and materials scattered. In the load and no-load branch are equipped with a number of self-aligning roller. If roller appear rotating not flexible or not turning phenomenon. The drag coefficient of roller operation by rolling into a slide, value was ten times to increase. The results will result in increased running resistance of belt conveyors, electric power consumption increases. As the roller rotation is not flexible, the friction between roller and conveyor belt by rolling friction into sliding friction, make the friction increase between the two, shorten the equipment life . Therefore, we must often replace a large number of idlers, conveyor belt, resulting in increased equipment maintenance, operating costs increased.Many factors for affect the flexibility of running rollers and life span, summarized in the following areas:a.Manufacturing quality of rollerRoller manufacturing problems mainly in the bearing stiffness is not enough, it is difficult to ensure precision of roller assembly, thereby constraining the flexibility of running roller.b.Sealed lubrication and the use of maintenanceMain factors of affect roller rotation not flexible include sealing and bearing lubrication problem. As the work environment of belt is more severe. Generally speaking, the dust are great on used site. The seal form of bearing have a great influence on the running flexibility for rollers. If sealed not well, Dirt is easy into bearing to cause the roller rotation is not flexible, In addition, bearing grease if using the general calcium base grease is easy to change color to dry, can not play a very good lubricant role.946 Lihua ZHAO and Yin LIN / Procedia Engineering 26 (2011) 942 9463.2. Solutionsa. In the roller manufacturing processes guarantee the accuracy requirements, For example, pressing bearing bore to achieve three precision, tube at both ends of dimensional tolerances, concentricity and ovality must meet national standards. The products have strict quality inspection to ensure that all products qualified.b.Sealed lubrication, in addition to manufacturing quality assurance, go with good lubricating materials, such as use of lithium-based grease, can improve the lubrication of bearings which extend the life of the roller is necessary.c.Bearing used to ball bearings support, plastic sealing ring labyrinth seal structure, this can ensure roller worked reasonable force, While ensuring dust effect good, resistance small, easy assembly and disassembly, easy to maintain, reduce conveyor operating costs.4. ConclusionWide range applications of belt conveyors, and the work environment is generally more difficult, to keep equipment running in good working condition, extend equipment life, improve the quality of operation, reduce operating costs has been the goal of engineering and technical personnel. Analyze and resolve the impact normal operation of the main problems, to ensure the good functioning of device, it is an important work of equipment maintenance. This paper analyzes the proposed method. Helpful improve site maintenance staff levels to solve practical problems, for practical project has important significance.References1yixiang Lang. Transportation machinery equipment in thermal power plant.MNortheast dianli university book; 1998.08.2lihua Zhao. Operation and Maintenance of Coal Handling System in Thermal Power Plant, J.Colliery Machine;2011,NO. 02.3lihua Zhao. Typical failure analysis and processing of belt conveyorJ.Hoisting and Conveying Machinery;2003,NO 10.4lihua Zhao. The adjustment method of conveyor belt deviation J. Colliery Machine. 2001. No.05.
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