Drive for a Belt Conveyor System, Method for Mounting a Drive on a Belt Conveyor System, and Belt Conveyor System

Abstract

A drive for a belt conveyor system includes a permanently excited synchronous motor having a stator and a rotor, wherein a gap size is formed between the rotor and the stator, and a holding device is provided, which is secured to the stator via a first securing device and to the rotor via a second securing device in order to provide secure assembly of the drive, such that the gap size is maintained, where the first securing device and/or the second securing device are detachably formed, such that an uninterrupted operation of the belt conveyor system is guaranteed.

Claims

1.-16. (canceled)

17. A drive for a belt conveyor system, comprising: a permanently excited synchronous motor having a stator and a rotor, the rotor and the stator having a gap size formed therebetween; and a holding device secured to the stator via a first securing device and to the rotor via a second securing device, the at least one of the first and second securing devices being configured to be releasable; wherein the holding device is structured such that an air gap is created between the holding device and the stator or rotor when the first or second securing devices are released.

18. The drive as claimed in claim 17, wherein at least the second securing device for releasing the connection of the holding device to the rotor is configured to be releasable.

19. The drive as claimed in claim 17, wherein the holding device is configured to accommodate a seal.

20. The drive as claimed in claim 17, wherein that the holding device is formed as an angled flange ring having a continuous circumference.

21. The drive as claimed in claim 17, wherein at least one of the first securing device and the second securing device comprises a screw.

22. The drive as claimed in claim 17, wherein the holding device is made of a metallic material.

23. The drive as claimed in claim 17, wherein the metallic material comprises steel.

24. A method for mounting a drive on a belt conveyor system comprising a drive roller arranged on a drive shaft, the drive comprising a permanently excited synchronous motor having a stator and a rotor, the method comprising: inserting the rotor into the stator; fixing the rotor in relation to the stator via a holding device which is secured to the stator via a first securing device and to the rotor via a second securing device, such that a gap size is maintained between the rotor and the stator; connecting the drive and the drive shaft to each other in a gearless manner; and releasing at least one of the first securing device and the second securing device.

25. The method as claimed in claim 24, further comprising: releasing at least the second securing device; and separating the rotor from the holding device.

26. The method as claimed in claim 24, wherein an air gap is created between the holding device and the stator or rotor when the first or second securing devices are released.

27. The method as claimed in claim 25, wherein an air gap is created between the holding device and the stator or rotor when the first or second securing devices are released.

28. The method as claimed in claim 26, further comprising: fitting a seal to the holding device.

29. The method as claimed in claim 24, wherein the holding device comprises an angled flange ring having a continuous circumference.

30. The method as claimed in claim 24, wherein the holding device is connected to at least one of the stator and rotor via screw connections.

31. The method as claimed in claim 30, wherein the holding device is made of a metallic material.

32. The method as claimed in claim 31, wherein the metallic material comprises steel.

33. The method as claimed in claim 24, wherein said the inserting and fixing the rotor are performed at a location other than an assembly site of subsequent steps.

34. The method as claimed in claim 24, wherein, for maintenance work on the belt conveyor system, at least one of the released first securing device and the second securing device are reused to establish a connection between the stator and the rotor, and the drive is separated from the drive shaft.

35. A belt conveyor system having the shaftless drive as claimed in claim 17.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Exemplary embodiments of the invention will be explained in detail with reference to a drawing, in which

[0025] FIG. 1 shows a longitudinal section of a first embodiment variant of a belt conveyor system having a direct drive and a holding device for the drive in accordance with the invention;

[0026] FIG. 2 shows a longitudinal section of the assembly of the belt conveyor system of FIG. 1;

[0027] FIG. 3 shows a longitudinal section of a second embodiment of a belt conveyor system having a direct drive and a holding device for the drive in accordance with the invention; and

[0028] FIG. 4 is a flowchart of the method in accordance with the invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0029] The same reference characters have the same meaning in the different figures.

[0030] FIG. 1 shows a schematic and greatly simplified view of a belt conveyor system 1 for heavy industry, in particular for the raw materials or mining industries. The belt conveyor system 1 is mounted on a supporting structure 2. The belt conveyor system 1 shown in FIG. 1 comprises a conveyor belt 3 and a drive 4 for driving the conveyor belt 3, a drive shaft 5, two drive shaft bearing arrangements 5a, 5b and a drive roller 6. Here, the drive roller 6 is made of solid material, but can equally be formed hollow. The drive roller 6 and the drive 4 are arranged between the two drive shaft bearing arrangements 5a, 5b.

[0031] A further drive motor can optionally be arranged on the drive shaft 5 to the side of the drive roller 6 on the side facing away from the drive motor 7. It is also possible to arrange further drive rollers 6 on the drive shaft 5.

[0032] In its original state prior to incorporation in the belt conveyor system 1, the drive 4 is a shaftless, bearing-free drive that comprises a permanently excited synchronous motor 7, also referred to as drive motor, having a stator 7a and a rotor 7b. The rotor 7b and the stator 7a are located in a motor housing 7c with which the stator 7a is fixedly connected. When the drive 4 is incorporated on the side of the motor housing 7c facing the drive roller 6, a seal 9 is fitted that protects the drive 4 against dust and moisture.

[0033] The drive shaft 5 and the drive motor 7 are connected to each other in gearless manner, with a coaxial arrangement of the rotor 7b and the drive shaft 5. The drive shaft 5 is guided through the rotor 7b and projects beyond the rotor 7b. In the illustrated exemplary embodiment, a shaft flange 11 is provided for securing the rotor 7b on the drive shaft 5. In this case, reference designator 12, serves to identify a hollow rotor shaft upon which a rotor package (including magnets) is mounted and can, however, be regarded as a component of the rotor 7b.

[0034] The spacing between the stator 7a and the rotor 7b is referred to as gap size S and maintenance of this spacing is decisive for the proper operation of the drive motor 7. In order to maintain this spacing during assembly of the drive 4 or during repair and maintenance work on the belt conveyor system 1, a holding device 13 is provided that fixes the stator 7a and the rotor 7b to each other.

[0035] In this case, the holding device 13 is formed as an angled, metallic flange ring made of steel and has essentially a continuous circumference. In this situation, the flange ring 13 is formed such that it bears on the motor housing 7c with a ring-shaped side and is connected to the motor housing 7c in the area of the contact surface and thus indirectly to the stator 7a. The flange ring 13 is also connected in a similar manner indirectly to the rotor 7b by a further ring-shaped side. A first securing device 15a is provided for securing the holding device 13 to the stator 7a or motor housing 7c and a second securing device 15b is provided for securing the holding device 13 to the rotor 7b (see FIG. 2), which securing devices comprise screws in the illustrated exemplary embodiment. However, it is also possible to use other types of securing devices, but it should be noted that they should be suitable for providing a releasable connection between the holding device 13 and the stator 7a or the rotor 7b.

[0036] With respect to FIG. 2, the assembly of the drive 4 and the function of the holding device 13 is as follows. In a first step, the rotor 7b is inserted into the stator 7a to produce the drive 4. Next, the rotor 7b is fixed in relation to the stator 7a by the holding device 13 which is secured to the stator 7a via the first screws 15a and is secured to the rotor 7b via the second screws 15b. In this way, the gap size S between the rotor 7b and the stator 7a is kept unchanged. The production of the drive 4 is performed in particular at a location other than the operating site of the belt conveyor system 1. The drive 4 can thus be transported as a unit, as illustrated in FIG. 2, for use in a belt conveyor system 1 and installed on site.

[0037] Only when the drive 4 is installed in the belt conveyor system 1 is the drive motor 7 fitted with a shaft, namely the drive shaft 5, which is connected to the rotor 7b in a gearless manner and is set in rotation by the rotor 7b.

[0038] The shaft flange 11 and the seal 9 are arranged on the drive shaft 5 in this case. When the drive 4 is installed on the drive shaft 5, indicated by the arrow P1, the connection is released via the screws 15b between the holding device 13 and the rotor 7b to establish the operating state of the drive 4 of FIG. 1, in which the rotor 7b is able to rotate. The connection 15b must not be released until the motor housing 7c has also been screwed to a bearing shield of the bearing 5b. This firstly ensures that the air gap S is maintained. In order to ensure that the rotary motion of the rotor 7b is not impeded by the holding device 13, the holding device 13 is moved to a spacing from the drive 4 so that an air gap L is created between the holding device 13 and the rotor 7b (see FIG. 1 and FIG. 2). The holding device 13, however, remains fixedly connected to the stator 7a and continues to serve as a support for the seal 9. In this situation, for example, the seal 9 is connected to the holding device 13 by way of the screws 15b.

[0039] Alternatively, it is also conceivable to release the screws 15a so that the holding device 13 is released from the stator and only remains secured to the rotor 7b and rotates therewith.

[0040] In order to complete the assembly of the drive 4, the drive shaft bearing arrangement 5b is also fitted on the drive shaft 5, as indicated by the arrow P2. In the exemplary illustrated embodiment, the drive shaft bearing arrangement 5b in the assembled state is integrated in the motor housing 7c.

[0041] FIG. 3 shows a schematic longitudinal section of a second drive 4 for a belt conveyor system 1. The drive 4 likewise comprises a drive shaft 5, two drive shaft bearing arrangements 5a, 5b, a drive roller 6 and a permanently excited drive motor 7 having a stator 7a and a rotor 7b. The difference from the first embodiment of the belt conveyor system lies in the fact that the drive shaft bearing arrangement 5b is not part of the motor housing 7c but is mounted on a separate bearing construction 17, which in particular is made of steel.

[0042] A major advantage of the arrangements described above is the good accessibility of the drive shaft bearing arrangements 5a, 5b for maintenance purposes without the need to remove the drive 4 at all. In the case of maintenance work, such as on the drive drum 6, the holding device 13 is connected to the rotor 7b again in order to fix the gap size S, and then the drive 4 can be removed.

[0043] FIG. 4 is a flowchart of the method for mounting a drive 4 on a belt conveyor system 1 comprising a drive roller 6 arranged on a drive shaft 5, where the drive 4 comprises a permanently excited synchronous motor 7 having a stator 7a and a rotor 7b. The method comprises inserting the rotor 7b into the stator 7a, as indicated in step 410.

[0044] Next, the rotor 7b is fixed in relation to the stator 7a via a holding device 13 which is secured to the stator 7b via a first securing device 15a and to the rotor 7b via a second securing device 15b, such that a gap size S is maintained between the rotor 7b and the stator 7a, as indicated in step 420.

[0045] Next, the drive 4 and the drive shaft 5 are connected to each other in a gearless manner, as indicated in step 430. At least one of the first securing device 15a and the second securing device 15b are now released, as indicated in step 440.

[0046] Thus, while there have been shown, described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.