Continuous belt conveyors are widely used in mining, metallurgy, coal and port industries. As an important part of the belt conveyor, the belt conveyor drum pulley requires high reliability. Belt conveyors are widely used in the transportation of materials such as ports, coal, power plants, etc. The drive roller is a key component of the belt conveyor, and its function is to transmit the torque provided by the drive device to the conveyor belt. According to the different bearing capacity of the drum, the belt conveyor drum pulley can be divided into a light drum, a medium drum and a heavy drum. The light drum is welded, that is, the web is welded with the barrel, the hub and the shaft are connected by a key, and the medium and heavy drum are cast welded. That is, the web and the hub are integrally cast, and then welded to the barrel, and the hub and the shaft are connected by expansion sleeves. The advantages of the expansion sleeve connection are: accurate positioning, large transmission torque, easy disassembly and assembly, and avoidance of axial swaying. The surface of the belt conveyor drum pulley is covered with rubber or ceramic to increase the coefficient of friction between the drive roller and the conveyor belt. Due to the heavy bearing capacity of the medium-sized drum and the heavy-duty drum, the design calculation is unreasonable, and it is easy to cause an accident such as a broken shaft of the belt conveyor drum pulley.
The belt conveyor drives the drum under stress conditions. According to the traditional theory, in the process of the change of the drum wrap angle from 0° to 180°, as the wrap angle increases, the combined force of the conveyor belt increases and the belt conveyor drum pulley stress increases accordingly. Engineers usually do not pay enough attention to the small wrap angle drums during design, often using thinner shells. In a coal mine, many small diameter and small wrap angles were changed in the production process. The ring weld cracking accident occurred in a short period of time, tearing a large number of conveyor belts, causing shutdown and production stoppage, causing great losses to production. Therefore, it is necessary to carry out finite element analysis on the same conveyor belt tension and different wrap angle reversing drums, and compare the influence of the change of the drum wrap angle on the roller stress distribution for the engineering designers. Taking the coal mine head to the drum as the basic model, a finite element model was established to carry out static analysis. Through the calculation of the same conveyor belt tension and different wrap angles, the equivalent stress distribution law in the middle of the drum shell, the hub and the shell weld, and the displacement distribution law in the middle of the shell are compared and analyzed. When the drum is changed to the working direction of the conveyor belt, the belt tension point and the running point tension of the conveyor belt are very different, which can be regarded as the equal tension and the pressure of the roller surface along the circumferential direction.
The head of the belt conveyor drum pulley is redirected to the drum for analysis, and the belt conveyor drum pulley is evenly distributed along the axial direction. Studies have shown that the results of the simple analysis of the drum alone and the overall analysis of the drum, shaft and expansion sleeve are the result. The calculation of the drive roller plays a very important role in the manufacture of the drum, but the manufacturing process of the drum can not be ignored. For example, the heat treatment technology of the shaft, the non-destructive testing method and the processing quality all determine the life of the drum. Therefore, in order to obtain high-quality products, the calculation must be accurate first, the design should be reasonable, and the processing technology must be guaranteed.