Multi-piece rollers for conveyors

Abstract

A multi-piece roller for a conveyor belt or chain includes a first part and a second part that mates with the first part to form a complete roller with a circular rim and a central hub for receiving a shaft. The central hub includes curved recesses molded into its sidewalls and locking recesses in its peripheral portion. The second part is inserted into the space in the first part and rotated to an engaged position, where the curved protrusions enter the molded curved recesses and the locking ridges engage the locking recesses to form a complete roller.

Description

[Technical Field]

[0001] Related Applications This application claims priority to U.S. Provisional Patent Application No. 63 / 450,150, entitled "Multi-Piece Roller for a Conveyor," filed March 6, 2023, the contents of which are incorporated herein by reference. [Background technology]

[0002] FIELD OF THE INVENTION The present invention relates generally to a multi-piece roller that can be assembled to a shaft in an endless conveyor belt system.

[0003] Conveyor belts are used in many industries to transport products from a first location to a second location. Conveyor belts typically form an endless belt loop stretched between drive and idler sprockets or rollers at each end of the conveying path. Articles transported on the conveyor belt are supported along the upper conveying path. The conveyor belt returns along the lower returnway. Return shoes or rollers are often used to minimize the maximum conveyor belt slack in the returnway. Return rollers typically extend across the width of the conveyor belt at selected locations along the returnway. Rollers may also be used to support the conveyor belt at the infeed end and / or other locations of the endless conveyor belt circuit. Attaching rollers, sprockets, and other components to the conveyor shaft can be difficult and tedious. Additionally, separate locking components are often required to secure the components in axial position along the shaft. Summary of the Invention

[0004] The multi-piece conveyor roller includes a base portion and a cap portion. The cap portion mates with the base portion and rotates to a locked position to form a complete roller with a circular rim and a central hub for holding a shaft. The central hub includes a molded curved recess in a sidewall. The cap portion is inserted into a space within the base portion and rotated to an engaged position, whereby the curved protrusion enters the molded curved recess to form a complete roller.

[0005] According to one embodiment, a roller for a conveyor belt includes a first roller component and a second roller component that mates with the first roller component to form a complete roller. The first roller component includes a curved peripheral portion that defines an outer rim that contacts the conveyor belt. The curved peripheral portion has a space formed by spaced-apart, opposing shaped walls. At least one shaped wall includes a locking recess. A hub for receiving a shaft is radially inward of the peripheral portion to receive the shaft. The hub includes a flat bottom wall, first and second side walls perpendicular to the flat bottom wall, and an open end opposite the flat bottom wall. The first and second side walls include the shaped recess. A connecting portion extends from the hub to the curved peripheral portion. The second roller component has a peripheral end that is inserted into an opening in the curved peripheral portion to complete the peripheral portion. The peripheral end includes a locking ridge configured to engage with the locking recess. The inner end includes a curved protrusion configured to be inserted into the open end of the hub and received in the shaped recess of the hub. The second roller component is configured to be inserted into the opening and open end in a first orientation and then rotated about the radial axis to a locked position to complete the peripheral portion and hub.

[0006] According to another aspect, a roller assembly includes a shaft including a plurality of alignment recesses in a peripheral surface thereof and a plurality of multi-piece rollers attached to the shaft. Each roller includes a first roller component and a second roller component that mates with the first roller component to form a complete roller. The first roller component has a curved peripheral portion including a space formed by opposing end walls, a locking recess in the end wall of the peripheral portion, a hub radially inward of the peripheral portion for receiving the shaft, and a connecting portion extending from the hub to the curved peripheral portion. The hub includes a flat bottom wall having alignment ridges that engage with the alignment recesses, first and second side walls perpendicular to the flat bottom wall, and an open end opposite the flat bottom wall. Molded recesses are formed in the first and second side walls. The second roller component has a peripheral end that is inserted into the opening in the curved peripheral portion to complete the peripheral portion. The peripheral end includes locking ridges configured to engage with the locking recesses. The second roller component has an inner end that is inserted into the open end of the hub. The inner end includes a curved protrusion configured to be received within a molded recess in the hub. A second roller component is configured to be inserted into the opening and open end in a first orientation and then rotated about the radial axis to a locked position to complete the peripheral portion and the hub.

[0007] According to another aspect, a method of assembling a multi-piece roller onto a shaft includes inserting the shaft through an opening in a peripheral portion of a first roller component; installing the shaft into a hub of the first roller component, the hub including a bottom flat wall and side walls perpendicular to the flat bottom wall; moving a second roller component into the opening in a direction parallel to the longitudinal axis of the shaft until a radial axis of the first roller component is aligned with a longitudinal axis of the second roller component; and rotating the second roller component about its radial axis until locking ridges on the second roller component engage locking recesses in the peripheral portion of the first roller component and a curved recess in an inner end of the second roller component enters a molded recess in the side wall of the hub. [Brief explanation of the drawings]

[0008] [Figure 1]FIG. 1 is a perspective view of a roller assembly for a conveyor including a plurality of multi-piece rollers mounted on a shaft. [Figure 2] FIG. 2 is an exploded view of the roller and shaft of FIG. [Figure 3] FIG. 3 is a perspective view of the cap portion of the roller of FIG. [Figure 4] FIG. 4 is a perspective view of the base portion of the roller of FIG. [Figure 5] FIG. 5 is a cross-sectional front view of the roller of FIG. [Figure 6] FIG. 6 is a cross-sectional perspective view of the roller of FIG. [Figure 7] 7A-7C illustrate the process of locking the cap portion onto the base portion and shaft of FIG. [Figure 8] FIG. 8 illustrates an embodiment of a roller assembly having alignment recesses in the body of the shaft according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] A multi-piece roller for engaging and supporting a conveyor belt includes multiple portions that interfit around a shaft. While the present invention is described below with reference to certain exemplary embodiments, the invention is not limited to these exemplary embodiments.

[0010] Referring to FIG. 1 , conveyor roller assembly 10 includes a plurality of multi-piece rollers 20, 22 mounted on mounting shaft 12. In one embodiment, conveyor rollers 20, 22 are returnway rollers mounted within a conveyor returnway to guide and / or support a conveyor belt as it returns from the discharge end to the infeed section of the conveyor. First roller 20 supports the center portion of the conveyor belt, while second, edge rollers 22 support the edge portions of the conveyor belt and include flanges 23 for receiving the edges of the conveyor belt. The conveyor belt can rotate conveyor roller assembly 10 as it travels over outer rims 160, 161 of conveyor rollers 20, 22. Those skilled in the art will recognize that the exemplary conveyor roller assembly can be implemented in any suitable location within a conveyor, such as the infeed section or other location where support for the conveyor belt is beneficial. Alternatively, the rollers 20, 22 may include drive elements to form a sprocket for driving a conveyor belt.

[0011] Each exemplary multi-piece roller 20, 22 includes two components: a first component, designated as a base portion 50, 51, which mounts the shaft 12, and a second component, designated as a cap portion 60, 61. The cap portion 60, 61 engages with the base portion 50, 51 to form a complete roller having a circular periphery and capable of supporting a conveyor belt. The exemplary cap portion 60, 61 rotates about a radial axis within an opening in the associated base portion 50, 51 to fit into a mating position. Each component 50, 51, 60, 61 may include one unitary piece or multiple interconnected sub-pieces.

[0012] 2-4, which show the multi-piece flange roller 22 and its components in detail, the exemplary base portion 51 is curved and spans most of the circumference of the roller except for the peripheral space 40, and the cap portion 61 is inserted into this space to complete the circumference when mated with the base portion 51. The center roller 20 is similar except for the flange portion 23.

[0013] The base portion 51 includes a collar or central hub 30 that defines a central opening 29 for receiving the shaft 12. The exemplary hub 30 and opening 29 are square, but may have any size, shape, or configuration suitable for receiving a shaft. The hub 30 includes three vertical walls: a bottom wall 31 and two side walls 32, 33. The hub 30 opens to a surrounding space 40. The cap portion 61 includes walls configured to complete and surround the hub 30, as described below.

[0014] The side walls 32, 33 further include an upper molded recess 38 for receiving a corresponding protrusion on the cap portion 61. An exemplary molded recess has curved side walls that curve around a radial axis 41 that extends through the hub 30 and the space 40, and arcuate top and bottom walls, such that the molded recess 38 tapers from a center point to each end side wall 32 or 33. The top and bottom walls of the molded recess have flat ends that intersect the side walls and arcuate edges that merge into the side walls. The molded recess 38 is spaced from the bottom wall 31 a distance slightly greater than the height of the corresponding shaft, such that when the shaft is installed in the hub 30, the molded recess 38 is exposed just above the shaft.

[0015] The bottom wall 31 of the hub includes alignment ridges 39 for locating the rollers on the associated shaft. The shaft 12 includes corresponding recesses for receiving the alignment ridges 39, as described below.

[0016] Hub portion 30 is formed within base portion 51 and connected to curved peripheral portion 52 of base portion 51 by spokes 28, although any suitable means, such as welding, for connecting central hub portion 30 to peripheral portion 52 may be used. An exemplary peripheral portion includes flange portion 23a, which is absent from central roller 20.

[0017] An opening 40 is formed from peripheral portion 52 into hub 30 to receive and lock an upper portion of cap portion 61. Aperture 40 is aligned with the open end of hub 30 and provides a passageway extending along radial axis 41 from the exterior of roller 22 to opening 29. Aperture 40 is defined by opposing curved concave surfaces 42, 44 adjacent outer surface 161 of rim 52.

[0018] 5 and 6, the opening 40 widens between the curved concave surfaces 42, 44 and the inner surface of the rim. In this exemplary embodiment, the tops of the curved concave surfaces 42, 44 are vertical (parallel to the radial axis 41) and the bottoms flare outward to form a horn shape. The bottom further includes a recess 46 for receiving a corresponding locking ridge on the cap portion 61, as described below.

[0019] The exemplary cap portion 61 is configured to be inserted into the opening 40 when in a first orientation and then rotated about the radial axis 41 to a locked position, as described below. Prior to inserting the cap portion 61, the shaft 12 is inserted into the central opening 29 through the opening 40 and the open end of the hub 30.

[0020] The exemplary cap portion 61 includes a peripheral edge 62 configured to complete the periphery of the roller 22, an inner edge 63 configured to complete the central opening 29, and connecting portions, shown as spokes 68, connecting the peripheral edge 62 and the inner edge 63. The spokes 68 extend along axes 43 that align with the radial axis 41 of the base portion 51 during formation of the complete roller.

[0021] The peripheral edge 62 includes an outer surface 65 that aligns with the outer surface 161 of the base portion rim 52 to form a complete perimeter 161. The peripheral edge 62 also includes a flange portion 23b that aligns with the base portion flange portion 23a to form a complete flange 23. The peripheral edge 62 has a substantially oval shape and has curved end walls 72, 74 designed to interface with the curved concave surfaces 42, 44 of the base portion opening 40. Shaped, angled locking shoulders 76, 78 extend below the curved end walls 72, 74 and flare to match the flared portion within the opening 40. The shaped, angled locking shoulders 76, 78 include one or more locking ridges 79. When the cap portion 61 is rotated about the radial axis 41, each locking ridge 79 locks into a corresponding recess 46 of the base portion 51 for locking engagement.

[0022] The exemplary peripheral edge 62 further includes a notch 75 in the flat sidewall that makes it easier to grip and rotate the cap portion 61 using fingers or a tool that can be inserted therein.

[0023] Inner end 63 includes flat side walls 83, 84 and curved locking projections 85, 87 extending from the end walls that are configured to be received within molded recess 38 of hub 30. Inner end 63 includes a flat inner wall 73 configured to abut and accommodate shaft 12.

[0024] 5 and 6, molded recess 38 receives curved locking projections 85, 87, flat inner wall 73 abuts the top of shaft 12, and peripheral end 62 is locked within space 40. The upper surfaces of locking shoulders 76, 78 abut the flared surface of opening 40, and locking ridge 79 is received within recess 46.

[0025] 7A-7C illustrate steps involved in assembling an exemplary embodiment of roller 22 to shaft 12. After shaft 12 is inserted through opening 40 into hub 30, cap portion 61 is inserted into space 40 and the open end of hub 30 in a first orientation, as shown in FIG. 7A. The exemplary first orientation is perpendicular to the assembled orientation. For example, flat side walls 83, 84 of inner end 63 of the cap portion abut against hub side walls 32, 33, the inner end fits into the open end of hub 30, and inner wall 73 abuts shaft 12. Bottom wall 73 of the cap portion slides along shaft 12 in a direction parallel to the longitudinal axis of shaft 12 until axes 41, 43 are aligned. The cap portion 61 is then rotated within the opening 40 about the longitudinal axis 43 and the radial axis 41 so that the curved locking projections 85, 87 enter the formed recesses 38 and the curved end walls 72, 74 rotate along the curved concave surfaces 42, 44, allowing the formed, angled locking shoulders 76, 78 to enter the widened portion of the opening 40. The cap portion 61 continues to rotate until the locking ridges 79 engage the locking mechanism 46 within the opening 40, locking the cap portion 61 to the base portion 51, as shown in FIG. 7C. In this locked position, the flange portions 23a, 23b are aligned with one another to form a complete flange, the outer surfaces 161, 165 are aligned to complete the periphery, and the inner end 63 of the cap portion 61 surrounds and locks the hub 30 to receive the shaft 12.

[0026] 8, the shaft 12 may include alignment recesses 18, 19 on its peripheral surface (i.e., the surface that will engage the flat bottom wall 31 of the corresponding hub 30) for receiving alignment ridges 39 on the roller hub. The location of the alignment recess 18 or 19 may vary depending on the type of roller being mounted in that region. For example, the alignment recess 18 on the inner roller 20 may be located in the center of the shaft, while the alignment recess on the edge roller 22 is offset from the center of the shaft to prevent assembly of the roller in the wrong axial position.

[0027] Although the present invention has been described in terms of a roller configuration, other configurations are possible and the present invention is not limited to the exemplary embodiments.

Claims

1. A roller for a conveyor belt, comprising: A first roller component, a curved peripheral portion defining an outer rim that contacts the conveyor belt, the curved peripheral portion having a space formed by spaced apart opposing shaped walls, at least one shaped wall including a locking recess; a hub radially inward of said peripheral portion for receiving a shaft, said hub including a flat bottom wall, first and second side walls perpendicular to said flat bottom wall, and an open end opposite said flat bottom wall, said first and second side walls including a formed recess; a connecting portion extending from the hub to the curved peripheral portion; a first roller component including: a second roller component, a peripheral edge that is inserted into an opening in the curved peripheral portion to complete the peripheral portion, the peripheral edge including locking ridges configured to engage with the locking recesses; an inner end inserted into the open end of the hub, the inner end including a curved protrusion configured to be received in the molded recess of the hub; a second roller component including: Including, The second roller component is configured to be inserted into the opening and open end in a first orientation and then rotated about a radial axis to a locked position to complete the peripheral portion and hub.

2. The roller of claim 1 , wherein the second roller component has a substantially elliptical shape.

3. The roller of claim 2 , wherein the peripheral edge includes a notch in a flat sidewall.

4. 2. The roller of claim 1, wherein opposing end walls of the curved peripheral portion of the first roller component include curved concave surfaces, and the peripheral end of the second roller component includes a curved end wall configured to abut the opposing end wall of the first roller component.

5. 2. The roller of claim 1, wherein the opposing end walls include a base that flares outwardly to form a flared shape, and the peripheral edge of the second roller component includes a contoured, angled locking shoulder below the curved end walls.

6. The roller of claim 5 , wherein the locking ridge is formed on a contoured, angled locking shoulder.

7. The roller of claim 1 , wherein the hub molded recess includes top and bottom walls that are arcuate.

8. 2. The roller of claim 1, wherein the molded recess is spaced from the flat bottom wall by a distance slightly greater than the height of a shaft received in the hub.

9. The roller of claim 1 , wherein the curved peripheral portion of the first roller component includes a flange and the peripheral edge of the second roller component includes a flange portion aligned with the flange.

10. The roller of claim 1 , wherein the flat bottom wall of the hub includes alignment ridges for locating the roller on an associated shaft.

11. 1. A roller assembly comprising: a shaft including a plurality of alignment recesses on a peripheral surface thereof; a plurality of multi-piece rollers mounted on the shaft, each roller comprising: a first roller component having a curved peripheral portion including a space formed by first opposing end walls, locking recesses in the end walls of the peripheral portion, a hub radially inward of the peripheral portion for receiving the shaft, the hub including a flat bottom wall having alignment ridges that engage with alignment recesses, first and second side walls perpendicular to the flat bottom wall, and an open end opposite the flat bottom wall, molded recesses formed in the first and second side walls, and a connecting portion extending from the hub to the curved peripheral portion; a second roller component having a peripheral edge inserted into the opening in the curved peripheral portion to complete the peripheral portion, the peripheral edge including locking ridges configured to engage with the locking recesses; a plurality of multi-piece rollers including: an inner end inserted into the open end of the hub, the inner end including a curved protrusion configured to be received in the molded recess of the hub; Including, The roller assembly is configured such that the second roller component is inserted into the opening and open end in a first orientation and then rotated about a radial axis to a locked position to complete the peripheral portion and hub.

12. 12. The roller assembly of claim 11, wherein a first multi-piece roller includes a registration ridge at the center of the hub and a second multi-piece roller includes a registration ridge offset from the center of the hub.

13. The roller assembly of claim 12 , wherein the first multi-piece roller includes a flange.

14. The roller of claim 11 , wherein the hub molded recess includes arcuate top and bottom walls.

15. 12. The roller of claim 11, wherein the opposing end walls include a base that flares outwardly to form a flared shape, and the peripheral edge of the second roller component includes an angled locking shoulder molded below the curved end walls.

16. A method for assembling a multi-piece roller onto a shaft, comprising: inserting the shaft through an opening in a peripheral portion of the first roller component; placing the shaft within a hub of the first roller component, the hub including a bottom flat wall and side walls perpendicular to the bottom flat wall; moving a second roller component into the opening in a direction parallel to the longitudinal axis of the shaft until the radial axis of the first roller component is aligned with the longitudinal axis of the second roller component; rotating the second roller component about the radial axis until locking ridges on the second roller component engage locking recesses on the peripheral portion of the first roller component and a curved recess on an inner end of the second roller component enters a molded recess in the sidewall of the hub; A method comprising:

17. 17. The method of claim 16, wherein the step of installing the hub includes engaging an alignment ridge on the bottom wall of the hub with an alignment recess on the shaft.

18. 17. The method of claim 16, wherein the rotating step includes inserting a tool into a notch formed in the second roller component to facilitate gripping and rotating the second roller component.

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