哪些因素影响托辊性能？托辊如何选择？

What factors affect the performance of the roller? How to choose the roller?

带式输送机在散状物料的输送中起着重要作用。托辊是带式输送机中的重要部件之一，一般情况下其造价在输送机中占第二位。输送机中运转部件最多的也是托辊，因此托辊的选择及性能直接影响着带式输送机的运行。本文分享影响托辊性能的因素及如何选择托辊。

Belt conveyor plays an important role in conveying bulk materials. The roller is one of the important parts of the belt conveyor, and its cost takes the second place in the conveyor. The most running parts in the conveyor are also the supporting rollers, so the selection and performance of the supporting rollers directly affect the operation of the belt conveyor. This article shares the factors affecting the performance of the idler and how to select the idler.

用户对托辊的性能要求主要有：

The requirements of the user to the performance of the roller are mainly:

①使用寿命；②工作的可靠性；③振动与噪声；④旋转阻力；⑤对环境的适应能力。

(1) service life; (2) reliability of work; (3) vibration and noise; (4) rotational resistance; (6) adaptability to the environment.

影响托辊性能的因素

Factors affecting the performance of the roller

托辊性能的好坏，是否能够满足用户的需要，主要取决于如下几个方面的因素：

Whether or not the performance of the idler can meet the needs of users depends mainly on the following factors:

托辊轴承的选择

Selection of roller bearing

目前主要使用的是深沟向心球轴承和圆锥滚子轴承。

At present, deep groove centrifugal ball bearings and tapered roller bearings are mainly used.

深沟向心球轴承

Deep groove centripetal ball bearing

特点：①可以做成大游隙，允许有较大的加工安装误差和轴的弯曲变形；②运转阻力略低于圆锥滚子轴承；③价格较低。

Features: (1) it can be made into large clearance, allowing greater machining and mounting errors and bending deformation of the shaft; 2. The running resistance is slightly lower than that of the tapered roller bearing; (3) the price is lower.

主要缺点：①抗冲击能力差；②不能承受较大的轴向力；③抗腐蚀能力差；④使用寿命低于圆锥滚子轴承；⑤在相同的承载能力下尺寸较圆锥滚子轴承大。

Main shortcomings: (1) poor impact resistance; (2) cannot bear large axial force; (3) poor corrosion resistance; (4) service life is lower than tapered roller bearing; 5. The size of the same bearing capacity is larger than that of tapered roller bearing.

圆锥滚子轴承

Tapered roller bearing

特点：

Characteristic:

①具有较大的径向和轴向承载能力；

(1) it has large radial and axial bearing capacity;

②在相同的承载能力和寿命情况下，尺寸小于球轴承；

2. Under the same bearing capacity and life condition, the dimension is smaller than the ball bearing.

③调节性能好，不管是轴向游隙还是预加负荷，均能按设计要求达到最佳性能；

3. Good adjustment performance, whether axial clearance or pre load, can achieve the best performance according to the design requirements.

④由于内外滚道可分离，安装拆卸十分方便；

4. Because the inside and outside raceway is detachable, installation and disassembly are very convenient.

⑤与深沟向心球轴承相比较，在相同的载荷和寿命条件下，价格较低；

5. Compared with deep groove spherical bearings, the price is lower under the same load and life conditions.

⑥具有自排污能力，由于圆锥滚子轴承固有的自动移油特点可从滚道接触区域除去任何微粒污染物，因而大大降低受工作环境污染程度；

(6) it has the ability of self discharge. Because of the inherent automatic oil shifting of tapered roller bearing, any particulate pollutants can be removed from the contact area of the raceway, thus greatly reducing the pollution degree of the working environment.

⑦具有较强的抗冲击能力。

It has strong anti impact ability.

缺点：①加工、装配精度要求高，加工和装配（包括受载后轴变形）对轴承寿命影响较大；②运转阻力略高于深沟向心球轴承。

Shortcomings: (1) the precision of machining and assembly is high, and the processing and assembly (including the rear axle deformation) has a great influence on the bearing life, and the running resistance is slightly higher than that of the deep groove centripetal ball bearing.

圆锥滚子轴承和深沟向心球轴承哪种更好要看具体情况，目前国内厂家多用球轴承，国外这两种都有。

Tapered roller bearings and deep groove centripetal bearings which is better depends on the specific circumstances. At present, domestic manufacturers use ball bearings mostly, and these two kinds abroad have.

密封结构及润滑方式

Sealing structure and lubrication method

影响托辊使用寿命和运转阻力的另一个重要因素是轴承密封结构和润滑方式。

Another important factor affecting the service life and running resistance of the idler is the bearing seal structure and lubrication mode.

密封结构有两种形式：

There are two forms of seal structure:

非接触式密封，这种密封方式运转阻力小，但密封效果稍差；

Non contact seal, this type of sealing has little operational resistance, but the sealing effect is slightly worse.

接触式密封，密封效果较非接触式好，但是运转阻力偏大。

The contact seal has better sealing effect than the non contact type, but the operation resistance is too large.

从润滑方式看有两种方式：

There are two ways to see from the way of lubrication:

一次性注油润滑，不适合长期运转的托辊，会导致运转后期阻力增大，同时轴承的寿命也较短；

The one-off oil injection lubrication, which is not suitable for long term running rollers, will lead to increased resistance at the later stage of operation, and at the same time, the bearing life is also shorter.

可注油式润滑方式，这种润滑方式特点是可以保持轴承处于良好的工作状态，同时又可以将轴承滚道内的污物排除，提高轴承的使用寿命，托辊运行阻力基本恒定。

Oil lubricated mode, which can keep the bearing in good working condition, and eliminate the dirt in the bearing raceway at the same time, improve the service life of the bearing, and the running resistance of the roller is basically constant.

托辊的选择

Selection of roller

市场上托辊种类很多，究竟那种托辊更适合用户的需要呢？这要用科学的计算分析方法，以便用户能够从中获得最大的经济效益。

There are many kinds of roller in the market. What kind of roller is more suitable for users? It is necessary to use scientific calculation and analysis methods so that users can get maximum economic benefits.

托辊载荷的计算

Calculation of the load of the roller

托辊载荷分为静载荷和动载荷，托辊的载荷计算研究还不十分完善，有些载荷的规律尚不清楚。

The load of roller is divided into static load and dynamic load. The load calculation of idler is not very perfect, and the law of some load is not clear.

托辊的静载荷计算中主要考虑物料及输送带的正压力，在弯曲段还应考虑输送带张力的作用，特别是在凹凸弧段。对槽型托辊受力分析主要是载荷在3个托辊上的分配问题，尤其是在凸弧段，目前多数计算都把中间托辊看作是受力最大的，按物料重的70%和输送带重的40%计算，但是侧托辊受载后两个轴承的受力不等，同时还有比较大的轴向力。

The static load calculation of the idler mainly considers the positive pressure of the material and the conveyor belt, and the tension of the conveyor belt should also be taken into account in the bending section, especially in the concave convex arc section. The stress analysis of the groove roller is mainly the distribution of the load on the 3 rollers, especially in the convex arc section. Most of the calculations regard the middle roller as the maximum force, according to the weight of the material 70% and the conveyor belt weight 40%, but the force of the two bearings is unequal after the side rollers are loaded, and there is a relatively large axial force. .

托辊的动载荷是托辊实际选型中必须加以考虑的。托辊动载荷是由多方面的因素产生的，主要有：

The dynamic load of idlers must be considered in the actual selection of idlers. The dynamic load of idlers is caused by many factors.

①托辊辊壳偏心转动时产生的动载荷；

(1) the dynamic load generated by the eccentric roll of the roller housing.

②托辊偏心转动与输送带相互作用而产生的动载荷；

(2) the dynamic load generated by the interaction between idler and the conveyor belt.

③输送带及物料运动中对托辊冲击产生的动载荷；

(3) the dynamic load caused by the impact of the idler on the conveyor belt and the material movement.

④输送带横向弯曲振动拍打托辊产生的动载荷；

(4) the dynamic load caused by the transverse bending vibration of the conveyor belt.

⑤输送带张力变化对过渡段托辊、弯曲段托辊产生的动载荷；

(5) the dynamic load caused by the tension change of the conveyor belt to the idler and bending section of the transition section.

⑥高速运行的输送带通过托辊时物料和输送带变形对侧托辊作用力，特别是物料中含有大块时其冲击力是最大的，目前这方面的研究还很少；

At the present time, the impact force of the high speed conveyer belt on the side rollers when the material and the conveyor belt are deformed when the material and the conveyer belt are deformed, especially when the material contains large blocks is the biggest, and the research in this respect is very few at present.

⑦转载处托辊受物料下落的冲击动载荷。正确地计算这些载荷对于选择托辊、估算托辊的使用寿命是非常重要的。

The dynamic load of the roller at the retransmission place is affected by the falling of the material. Correctly calculating these loads is very important for selecting idlers and estimating the service life of idlers.

托辊的寿命与可靠性的估算

Estimation of the life and reliability of the roller

在对环境和托辊的受力进行分析之后，就要对托辊的寿命和可靠性进行估算，这项工作应当由设计单位和托辊的制造商联合完成，并能向用户提供分析报告。托辊的寿命及可靠性的分析对用户来讲是很重要的，是用户技术经济评价的重要尺度。

After the analysis of the force of the environment and the roller, the life and reliability of the roller should be estimated. This work should be completed by the manufacturer of the design unit and the manufacturer of the roller, and can provide the analysis report to the user. The analysis of the life and reliability of idlers is very important for users, and is also an important yardstick for users' technical and economic evaluation.

托辊制造商实力

Strength of roller manufacturer

影响托辊质量的一个很重要的因素是托辊制造商的技术力量、技术装备、科学的管理和良好的服务意识，生产商应当能为用户提供完整的技术服

One of the most important factors affecting the quality of the roller is the technical force, technical equipment, scientific management and good service awareness of the manufacturer, and the manufacturer should be able to provide a complete technical suit for the user.