JP3984141B2 - Guide roller manufacturing method and cord-reinforced rubber extrusion apparatus used therefor - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a guide roller manufacturing method in which a rope is guided on an outer peripheral surface and an inner peripheral surface is supported by a support portion, and a cord-reinforced rubber extrusion device used therefor.
[0002]
[Prior art]
Guide rollers for guiding ropes are used in gondolas, ski lifts, ropeways, and the like. Such guide rollers are disclosed in, for example, Japanese Patent Laid-Open Nos. 7-315214 and 5-162637. A general structure of the guide roller will be described with reference to FIG.
[0003]
FIG. 7 is a cross-sectional view of the guide roller cut along a plane passing through the rotation center CE. The guide roller 100 includes a rubber layer 101 that does not include a reinforcing cord made of fiber, and a reinforcing layer 102 made of a reinforcing cord. A shallow V-shaped guide groove 101a is formed on the outer peripheral surface of the rubber layer 101, and the rope R is guided. Further, the inner peripheral surface of the rubber layer 101 is supported by a pipe 103 (support portion). The reason why the reinforcing layer 102 is provided is that a large stress acts between the support portion and the strength while the rotational force from the rope R is acting to ensure the strength. On the other hand, the outer peripheral surface is not reinforced with a reinforcing cord in order to absorb vibration and impact from the rope.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 7-315214, FIGS. 1-4, etc. [Patent Document 2]
Japanese Patent Laid-Open No. 5-162637, FIG. 1, FIG. 2, etc.
Conventionally, the manufacture of the guide roller has a process of winding a fiber as a reinforcing cord and a process of winding a rubber. Since these are performed in separate processes, there is a problem that the manufacturing time becomes long. In addition, since the interlayer rigidity between different materials (fiber and rubber) changes abruptly, shearing force is generated when a high load is applied, causing delamination. Further, since a large stress acts on the central portion in the width direction (point P in FIG. 7) of the inner peripheral surface of the guide roller, it is easy to break. This is considered to be because, in the structure as shown in FIG. 7 (the reinforcing cords are uniformly arranged in the width direction), the stress distribution becomes non-uniform and the largest stress acts on the central portion.
[0005]
The present invention has been made in view of the above circumstances, and the problem is that a guide roller manufacturing method capable of improving the problem of delamination between different materials and the breaking of a rubber layer, and a cord-reinforced rubber used therefor An extrusion apparatus is provided.
[Means for Solving the Problems]
In order to solve the above problems, a method for manufacturing a guide roller according to the present invention includes:
A method of manufacturing a guide roller in which a rope is guided by an outer peripheral surface, and an inner peripheral surface is supported by a support part,
A step of extruding and molding a plurality of thread-like non-reinforcing rubbers that do not include a reinforcing cord and / or a thread-like cord reinforcing rubber covered with a reinforcing cord;
Controlling the number of cord reinforced rubbers contained in a plurality of thread-like rubbers to be extruded; and
Winding the extruded rubber thread around a molding drum, and sequentially forming a rubber layer from the inner peripheral surface side toward the outer peripheral surface side,
In the controlling step, the number of reinforcing cords is controlled so as to decrease from the inner peripheral surface to the outer peripheral surface.
[0006]
The actions and effects of this manufacturing method are as follows. First, a thread-like cord reinforced rubber in which a reinforcing cord is covered with rubber by extrusion molding and / or a thread-like non-reinforced rubber is used. A plurality of thread-like rubbers are extruded in a state where they are arranged side by side, but when all of the plurality are cord-reinforced rubber, when all of the plurality are non-reinforced rubber, some of the plurality are cord-reinforced rubber. Three types of extrusion molding are possible when a part is non-reinforced rubber. In this way, the reinforcing cord and the rubber are not separately wound, but the cord reinforcing rubber in which the cord is covered with the rubber in advance is used, so that the problem of delamination can be reduced or eliminated. Further, when winding around the forming drum, the number of reinforcing cords can be increased on the inner peripheral surface side, and the number of reinforcing cords can be gradually reduced toward the outer peripheral surface side. Thereby, when the rotational force from a rope acts, a stress can be made uniform. As a result, it is possible to provide a guide roller manufacturing method capable of improving the problem of delamination between different materials and the breaking of the rubber layer.
As a preferred embodiment of the present invention, there is an example in which the number of reinforcing cords is controlled so as to increase toward the center in the width direction of the guide roller.
As a result, the center in the guide width direction where the rotational force from the rope is maximized can be particularly reinforced, and the center portion can be prevented from breaking.
[0007]
As another preferred embodiment of the present invention, switching from the cord-reinforced rubber to the non-reinforced rubber is performed by stopping the supply of the reinforcing cord.
[0008]
In order to reduce the number of reinforcing cords toward the outer peripheral side, the supply of reinforcing cords may be stopped for a specific number of cord reinforcing rubbers among the plurality of cord reinforcing rubbers. Thereby, unreinforced rubber that is not reinforced can be extruded. That is, the number (density) of reinforcing cords can be controlled depending on whether or not the reinforcing cords are supplied.
[0009]
Yet another preferred embodiment of the present invention is one in which the reinforcing cord is cut before or after the die for extruding the thread-like rubber.
[0010]
By cutting the reinforcement cord, the supply of the reinforcement cord can be easily stopped. For example, it can be cut by heat.
[0011]
The cord-reinforced rubber extrusion device used in the guide roller manufacturing method of the present invention is
A cord supply unit for supplying a plurality of cords, a rubber supply unit for supplying a rubber material to be coated on the cords, and a die for extruding the plurality of rubber-coated cords in a row. It is characterized by.
[0012]
With such an extrusion device, cord-reinforced rubber or non-reinforced rubber can be extruded from a die.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of a guide roller manufacturing method according to the present invention will be described with reference to the drawings. 1A and 1B are diagrams showing a configuration of a cord-reinforced rubber extrusion device, where FIG. 1A is a cross-sectional view, FIG. 1B is a front view, and FIG. 2 is a perspective view showing an outline of the device.
[0014]
<Device configuration>
The main part of the apparatus is composed of a part for extruding a cord-reinforced rubber. A code is supplied to the code supply unit 1 from the direction of arrow A in FIG. This cord is a reinforcing cord that reinforces the rubber layer, and is formed of metal fiber, synthetic fiber, chemical fiber, or the like. A plurality of codes are supplied in a line.
[0015]
A passage through which the cord passes is provided in the center of the main body 3. A cord guide 6 is fastened to the main body 3 via a set screw 4 and a nut 5. A passage through which the cord passes is formed in the central portion of the cord guide 6. The passage of the cord is formed in a horizontal direction, but the passage of the rubber material is inclined (30 to 45 degrees) with respect to the passage of the cord. The rubber material is supplied from the arrow B direction. An extension nozzle 7 is inclined and attached above the main body 3, and a flange 8 for attaching a small extruder (not shown) is further attached to the extension nozzle 7.
[0016]
The crossing position of the cord passage and the rubber material passage is the joining portion 9, and the cord is covered with the rubber material. A die 11 (corresponding to a cap part) is attached to the front end of the main body 3 with a fixing screw 10. The dice 11 are formed with a plurality of openings 11a in a row. The die 11 is extruded from a thread-like cord reinforcing rubber.
[0017]
A converging roll 20 is provided in front of the die 11. The converging roll 20 also has a function of guiding the width direction of a plurality of cord-reinforced rubbers in an extruded shape. FIG. 3 is an enlarged view showing the configuration of the converging roll 20. The converging roll 20 includes a shaft portion 21 and a pair of movement guides 22 that can move along the shaft portion 21. (A) shows a state in which the movement guide 22 is narrowed, and (b) shows a state in which the movement guide 22 is widened. That is, the moving guide 22 and a mechanism for moving the moving guide 22 function as a guide width changing mechanism. The mechanism for moving the movement guide 22 can be constituted by a motor or a transmission mechanism (gear, pinion rack, cam, etc.).
[0018]
A plurality of cord reinforcing rubbers C are guided between the pair of movement guides 22 described above. In addition, by changing the guide width in this way, the density state of the cords in a plurality of cord reinforcing rubbers to be manufactured (a composite of the plurality of cords and rubber may be referred to as a multi cord) is changed. Can do. Note that the surface of the movement guide 22 that contacts the cord reinforcing rubber is an inclined surface to facilitate the guide.
[0019]
FIG. 3 (c) shows the positional relationship of the cord reinforcing rubber immediately after being extruded from the die 11, and the adjacent cord reinforcing rubbers C are adjacent to each other by the converging roll 20 although a gap is open. The cord reinforcing rubber C is joined. The cord reinforcing rubber C has a fiber C1 disposed at the center and is covered with a rubber C2 so as to surround the periphery thereof. Therefore, when wound around the molding drum 12, the plurality of string-like rubbers in a row form strip rubber.
[0020]
The cross-sectional shape of the cord reinforcing rubber C is not limited to a specific cross-sectional shape, but an elliptical shape is preferable as shown in FIG. The major axis direction of the ellipse coincides with the width direction of the multicode. If an elliptical shape is used, even if the cord density is sparse as shown in FIG. 3B, the bonding between adjacent cord reinforcing rubbers can be maintained. Any shape is acceptable as long as it is not a pure ellipse but is close to an ellipse (a horizontally long shape such as an ellipse). Moreover, it is good also as a horizontally long rectangular shape. Furthermore, a square cross section may be used. In addition, about the opening part 11a, the area which a rubber material passes is set so that it may become larger than the area which a reinforcement cord occupies.
[0021]
As illustrated in FIG. 1A, the die 11 is provided with nine openings 11a in a horizontal row, and nine cord reinforcing rubbers are extruded side by side. As will be described later, the cord reinforcement rubber does not come out from all the openings 11a, but the presence or absence of the supply of the reinforcement cord can be controlled. Therefore, unreinforced rubber that is not reinforced can be extruded from the opening 11a. That is, nine thread-like rubbers are extruded from the opening 11a in the following manner.
[0022]
(1) Nine cord reinforcement rubbers (2) Nine reinforcement rubbers (3) Of the nine, some are cord reinforcement rubbers and the rest are non-reinforcement rubbers. The number is not limited to nine Of course. The number can be set between several to several tens.
[0023]
<Manufacturing method>
Next, a specific manufacturing method will be described with reference to FIGS. FIG. 4 is a cross-sectional view in which a part of the guide roll 30 is broken. The rubber layer has a five-layer structure including a first rubber layer S1 to a fifth rubber layer S5. The rubber layers S1 to S4 are reinforced by the reinforcing cord, but the fifth rubber layer S5 is not reinforced. Specific dimensions of the guide roll are an inner diameter of 300 mm, an outer diameter of 420 mm (thickness of 60 mm), and a width of 80 mm. The number and thickness of the reinforcing cords in each rubber layer are 16 mm for the first rubber layer S1, 3 mm for the second rubber layer S2, 3 mm for the third rubber layer S3, and 4 mm for the fourth rubber layer. S4 is 6 mm and 3 mm, and the fifth rubber layer S5 is a natural rubber which does not include a reinforcing cord and has a hardness of 70 °. The same rubber is used in the other rubber layers S1 to S4. The number of reinforcing cords is gradually reduced as it goes to the outer peripheral surface, so that a sudden change in rigidity does not occur.
[0024]
A guide roller having such a layer structure can be manufactured by sequentially winding a multi-cord around a forming drum 12 as shown in FIG. The formation of the rubber layer starts from the inner peripheral surface side of the guide roller and is gradually wound around the outer peripheral surface side. The adjustment of the number of fibers will be described with reference to FIG.
[0025]
In FIG. 6A, it is assumed that nine cord reinforcing rubbers are initially supplied. For easy understanding, numbers 1 to 9 are assigned. The nine cord reinforcing rubbers C extruded from the die 11 are guided by the moving guide 22 of the converging roll 20. The width dimension guided at this time is represented by W ₁ .
[0026]
Next, the supply of reinforcing cords for numbers 3 and 7 is stopped. As a result, seven cord-reinforced rubbers and two non-reinforced rubbers are extruded from the die. The guide width at this time is W ₂ , which is slightly narrower than W ₁ . Further, as the step proceeds, the supply of reinforcing cords for numbers 3, 6, and 7 is stopped. As a result, six reinforcing cords and three non-reinforcing rubbers are extruded. Further, the guide width W ₃ is further narrower than W ₂ .
[0027]
That is _, by stopping the supply of _the reinforcing cord, the rubber is switched from the cord-reinforced rubber to the non-reinforced rubber. Conversely, by restarting the supply of the reinforcing cord, the rubber is switched from the non-reinforced rubber to the reinforced rubber. Various modifications can be considered for the mode of stopping the supply. For example, the supply of reinforcing cords at both ends in the width direction may be stopped. In this case, the density of the reinforcing cord does not change. Various modifications can be considered for setting the width dimension of the movement guide 22. For example, it is not necessary to change the width dimension.
[0028]
In FIG. 4, the fifth rubber layer S5 is a rubber layer not including a reinforcing cord. About such a rubber layer, if it sets to the state which does not supply a reinforcement cord at all using the extrusion apparatus shown in FIG. 1, the rubber layer which does not contain a reinforcement cord can be manufactured. As another manufacturing method, as shown in FIG. 5, the fifth rubber layer S5 is manufactured as a strip rubber having a desired cross-sectional shape with another extrusion device, and this is manufactured from the rubber layers S1 to S4. You may make it wind up on what you did. Since the fifth rubber layer S5 does not include a reinforcing cord, the manufacturing time is faster when the fifth rubber layer S5 is manufactured using the strip rubber.
[0029]
Various modifications of the method of stopping the supply of the reinforcing cord can be considered. The reinforcing cord is supplied by a supply device (not shown), and can be stopped by applying a brake to the supply. This is because if the brake is applied, the reinforcing cord can be cut. Of the plurality of reinforcement cords, which reinforcement cord is to be braked can be arbitrarily set.
[0030]
In addition, there is a method of cutting the reinforcing cord at any position before and after the die 11. The size of the opening 11a of the die 11 is sufficiently larger than the diameter of the reinforcement cord, and the reinforcement cord is heat-cut after the die 11 to facilitate simultaneous extrusion molding of the cord reinforcement rubber again. Can do. For example, a roller cutter can be used for cutting.
[0031]
Nylon, aramid, and polyester are effective as the fiber material of the reinforcing cord, but are not limited to a specific material. The reinforcing cord and rubber are effective even if they are not bonded, but are preferably bonded from the viewpoint of fatigue when subjected to repeated loads.
[0032]
<Effect>
The guide roller manufactured according to the present invention has the following operations and effects. As the rubber material, soft rubber having sufficient vibration absorption is used. Even if an impact load is applied, the load can be dispersed over a wide range to prevent the rubber from breaking. On the inner peripheral surface side, sufficient rigidity is secured by the reinforcing cord, and the outer peripheral surface that the rope contacts is made soft. Further, the distribution of the number of reinforcing cords is increased as the center portion of the guide roller is increased, and as the distance from the inner peripheral surface is increased. That is, the strength of the guide roller becomes stronger toward the center in the width direction. On the other hand, the rotational force received from the rope is greater at the center. In the guide roller according to the present invention, the stress is uniform over the width direction. Due to the contact with the rope, the strain on the outer surface is 10 to 20%, but the amount of strain decreases as the inner layer is reached. Thereby, the gap between the innermost first rubber layer S1 and the support portion is eliminated. In the case of the conventional structure, the rubber is ruptured at the central portion in the width direction where the strain is the largest. However, in the present invention, the stress (that is, the strain) is uniform in the width direction, so that the rupture is less likely to occur.
[0033]
Furthermore, in the manufacturing method according to the present invention, the rubber layer reinforced with the cord reinforcing rubber is formed. Conventionally, winding of the reinforcing cord and winding of the rubber layer were separate processes, so that the manufacturing time was increased and there was a problem of delamination between different materials. Does not occur (or does not occur at all). Moreover, in the state exposed to rainwater, rainwater permeates from the end of the fiber, and there is no possibility of causing deterioration and peeling.
[0034]
<Experimental result>
A comparative experiment was performed between the configuration of the present invention and the configuration of the conventional product. The specific dimensions of the guide roller of the present invention are as already described with reference to FIG. For the conventional product, the outer dimensions were the same, and the innermost layer was wound with 3 layers of 1260 d / 2 (1260 denier / 2 twisted) polyester sudder records. This was subjected to a rotation test with a 180 ° endless rope, and the rope load was 500 kg and the rope speed was 5 m / sec.
[0035]
When the test was conducted for 150 hours, the conventional product slipped between the guide roller and the rim (support portion). On the other hand, the product of the present invention was not abnormal after the 300-hour test. Further, the conventional product peeled between the reinforcing cord and the rubber after the 260-hour test. This confirmed that the production method according to the present invention was excellent.
[0036]
The extrusion apparatus used in the present invention preferably has the ability to increase the screw rotation speed when the rubber supply amount is small and to automatically decrease the screw rotation speed when the rubber supply amount is large. Moreover, the structure which mixes the rubber | gum from several extruders by making a plurality of extruder parts into the extrusion front end side (die side) is also employable.
[Brief description of the drawings]
FIG. 1 is a diagram showing a configuration of a cord-reinforced rubber extrusion device. FIG. 2 is a perspective view showing a configuration of a cord-reinforced rubber extrusion device. FIG. 3 is a diagram showing a configuration of a converging roll. FIG. 5 is a diagram illustrating a method of laminating a rubber layer of a guide roll. FIG. 6 is a diagram illustrating a supply form of thread-like rubber. FIG. 7 is a diagram illustrating a structure of a guide roller according to the prior art. Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Code supply part 2 Rubber supply part 11 Dice 11a Opening part 12 Molding drum 20 Converging roll 22 Movement guide 30 Guide roll R Rope C Code reinforcement rubber S1-S5 Rubber layer

Claims (5)

A method of manufacturing a guide roller in which a rope is guided by an outer peripheral surface, and an inner peripheral surface is supported by a support part,
A step of extruding and molding a plurality of thread-like non-reinforcing rubbers that do not include a reinforcing cord and / or a thread-like cord reinforcing rubber covered with a reinforcing cord;
Controlling the number of cord reinforced rubbers contained in a plurality of thread-like rubbers to be extruded; and
Winding the extruded rubber thread around a molding drum, and sequentially forming a rubber layer from the inner peripheral surface side toward the outer peripheral surface side,
In the step of controlling, the guide roller manufacturing method is characterized in that the number of reinforcing cords is controlled to decrease in the direction from the inner peripheral surface to the outer peripheral surface. The guide roller manufacturing method according to claim 1, wherein the number of reinforcing cords is controlled to increase toward the center in the width direction of the guide roller. The guide roller manufacturing method according to claim 1 or 2, wherein the switching from the cord-reinforced rubber to the non-reinforced rubber is performed by stopping the supply of the reinforcing cord. 4. The method for manufacturing a guide roller according to claim 3, wherein the reinforcing cord is cut before or after the die for extruding the thread-like rubber. A cord-reinforced rubber extrusion device used in the method for producing a guide roller according to any one of claims 1 to 4,
A cord provided with a cord supply portion for supplying a plurality of cords, a rubber supply portion for supplying a rubber material to be coated on the cords, and a die for extruding the plurality of rubber-coated cords in a row Reinforced rubber extrusion equipment.

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