Analysis And Research On The Failure Mechanism Of Belt Conveyor Pulley

The pulley is not only an important part of the belt conveyor,but also a very vulnerable part.And its service life seriously affects the normal operation and production of belt conveyor.This paper starts with the form of pulley failure.And the mathematical model of the pulley structure is set up.The distribution of stress in the pulley is studied,carried out the qualitative and quantitative research,and carried out the numerical simulation.The failure mechanism of pulley is studied,and found the real cause of the failure.The corresponding improvement measures are put forward to provide valuable theoretical basis for guiding the application practiceThere are five chapters in this paper.In the first chapter,according to the damage of the pulley in the belt conveyor work scene,the following forms of pulley failure are summarized as follows:pulley rubber surface degumming failure,pulley weld cracking failure and pulley rubber surface abrasion failure.The second chapter mainly introduces the pulley structure,classification and the reason of the pulley failure.In the third chapter,the mathematical model of the cold vulcanization adhesive and hot vulcanization adhesive is set up separately,according to the different forms of the adhesive tape of the belt conveyor pulley.Then the shear stress formula of binder is derived.The influence factors of shear stress are analyzed qualitatively and quantitatively.By numerical simulation,the influence of adhesive thickness,output tension of pulley separation point,friction coefficient,surrounding angle,etc on the shear stress of the binder is compared under two kinds of adhesive form.The results show that the hot vulcanized rubber pulley can bear greater output tension and get greater surrounding angle.And some control measures are put forward for pulley rubber surface degumming.In the fourth chapter,aiming at cracking failure of the welding seam,the failure analysis is carried out in two aspects:crack initiation and crack propagation.For weld crack initiation,it can be attributed to the results of stress concentration and residual stress at weld.Aiming at the stress concentration of weld,a stress concentration coefficient mathematical model is established,and simulated the influence factors by MATLAB software.Aiming at weld residual stress,ANSYS software was used for numerical simulation analysis,and the stress distribution of weld under different welding speed and welding current was compared.The results show that the speed of welding is faster,and the greater the peak value of residual stress at the weld.When the welding current is greater,the residual stress peak is greater.However,the change of the two parameters has little effect on the change of the peak position of weld residual stress.For analysis of weld crack propagation mechanism,the mathematical model of crack propagation is established,and derivating the stress intensity factor formula for slippery crack.Then the cause of the weld crack defect is analyzed,and the corresponding control measures are put forward to control the fracture failure of the weld.In the fifth chapter,aiming at pulley surface abrasion,the mechanical model of pulley rubber surface abrasion is established,according to the abrasion of pulley rubber surface,and derivating the formula of the abrasion of pulley rubber surface.Through simulation,the influence of various factors on the abrasion of pulley rubber surface is obtained.The results show that the tension of belt,the sliding angle,the distance between the wire rope in the belt and the diameter of the wire rope in the belt have different influence on the rubber surface of the pulley,in which the most serious is the belt tension.The control of the distance between the wire rope in the belt and the diameter of the wire rope in the belt is of great theoretical significance to the development of a new energy saving belt.