How To Optimize And Improve The Chain Wheel Parameter Design Of Apron Feeder
As a short-distance transfer and conveying equipment for large and super-large crushing stations, the heavy apron feeder is primarily utilized for material transfer operations in the feeding hopper of the out-break system. Its main components include the driving device, main shaft assembly, chain belt mechanism, support structure, tensioning unit, frame, guard plate hopper, etc. The driving chain wheel, as a critical component of the apron feeder, is located within the main shaft assembly. It converts the rotational motion transmitted by the driving device into linear motion via the chain belt mechanism, thereby achieving material conveyance. In recent years, foreign scholars have made significant advancements in research on the driving chain wheel. Through multiple experiments, an empirical formula for the tension of the tight edge was proposed. Experimental results demonstrated that at low rotational speeds of the chain wheel, the dynamic load of the chain has minimal impact on the force exerted on the chain links and can be considered a quasi-static situation. By considering the elastic deformation of the chain plate rollers and their own weight, a static force model of the chain and chain wheel in the engagement area was established based on the complete standard toothed chain wheel. The force conditions of the chain drive system were obtained by solving using the newton-raphson numerical method. For the apron feeder chain, both the actual tooth profile of the chain wheel and the simplified semi-tooth profile were analyzed. A multi-body dynamics model of the apron feeder chain drive was established, focusing on analyzing changes in contact force and tension during meshing. The solution results of the mathematical model were compared with software simulation results.
In recent years, a series of related studies have been conducted on the driving chain wheel of apron feeders. The calculation method of the circumferential force of the chain wheel was introduced. Through theoretical calculations, the relationship between material thickness and chain speed was analyzed, leading to the conclusion that controlling feeding thickness impacts chain selection and service life. Gu rentao calculated the tight edge tension and loose edge tension of the chain wheel, thereby analyzing the elastic deformation of the inner and outer chain links and the elastic deformation of the chain wheel. Subsequently, the standard tooth profile of the chain wheel was corrected to obtain a new non-standard chain wheel mesh. Using the bmx module of pro-e software, the size of the chain wheel was optimized to achieve the optimal tooth profile of the chain wheel. Finite element analysis of the force conditions of the chain wheel and chain was conducted using ansys software. This analysis identified parts prone to damage on the chain wheel and optimized structural dimensions based on the maximum equivalent stress value of relevant parts as the objective function, thereby reducing the working intensity of the chain wheel and extending its service life.
The forces acting on the chain wheel were simplified, and mechanics and modal analysis of the chain wheel were performed using pro/engineer mechanica. Based on existing research results, current studies mainly focus on the relationship between tooth calculation parameters and the force and deformation of the thick-moving chain wheel. In the aforementioned studies, only certain chain wheel design parameters were considered to influence the chain drive system. Taking a specific model of a self-moving crushing station’s heavy apron feeder as the research object, theoretical calculations were used to determine the external load borne by the driving chain wheel during the movement of the heavy apron feeder. A three-dimensional parametric dynamic model of the moving chain wheel was established in finite element analysis software to minimize system mass and stress. The pitch circle diameter, roller outer diameter, and tooth width of the driving chain wheel were used as design variables. Multi-objective genetic algorithms were employed to optimize the chain wheel structure design.
