Motorized conveyor roller

Abstract

Motorized conveyor roller (1), comprising: a roller tube (5), an axle shaft (4), a drive assembly (10), the drive assembly (10) is adapted to provide a drive force to the roller tube (5), powering a rotational movement of the roller tube (5) over the axle shaft (4); the drive assembly (10) comprises: - a motor (13) - a brake (12), - a cylindrical housing (15), - a control (11), adapted to control operation of the motor (13), wherein the motor (13) and the brake (12) are held within the cylindrical housing (15) by a press fit connection, wherein the brake (12) is located axially between the motor (13) and the control (11), wherein the motor (13) is electrically connected to the control (11) by a motor contacting (M), wherein the motor contacting (M) is axially passing the brake (12); wherein the motor contacting (M) comprises at least one motor contacting plug (MP) and at least one motor contacting socket (MS) connected to each other.

Description

Motorized Conveyor RollerBackground of the inventionThe invention refers to a motorized conveyor roller.US 2002 / 0007988 A1 and EP 4 175 129 A1 disclose a motor incorporating roller having a roller body and a motor unit inserted into said roller body. The motor unit comprising an outer cylinder, a motor, a brake member and a circuit board. The outer cylinder incorporates the motor, the brake member and the circuit board, wherein the brake member is located between the motor and the circuit board in the outer cylinder. The circuit board is wired to the motor and the brake member in the outer cylinder.Thereby EP 4 175 129 A1 points out a particular topic, how to implement the wiring between the circuit board and the motor in case that the brake is located therebetween. Since all components are arranged within a narrow space, it is not trivial to provide said wiring in a manner to support easy assembly of the components.DE 20 2018 105 651 U, also published as CN 211 239 620 U, discloses a driving device for a dimming device, in other words a roller shutter drive. The roller shutter drive has a motor unit, a brake unit and a control, where the brake unit is located axially between the motor unit and the control. The drive force is transmitted via a load shaft to the separate shutter device. No roller tube is provided to contact an object to be conveyed, so that the roller shutter device can not be considered as a conveyor roller. The electrical connector connecting the motor unit with the control is integrated into the housing of the brake in the form of a wiring element (see DE 20 2015 105 651 U,

[0037] ).It is the object of the present invention to provide an improved motorized roller having an internal brake.Summary of the inventionThe problem is solved by a roller and a method according to the main claims; embodiments are subject to the subclaims and the description.The inventive motorized conveyor roller includes a roller tube, which in particular provides a support surface for an object to be conveyed. It has an axle shaft and a drive assembly that provides a drive force to the roller tube, enabling a tube’s rotational movement over the axle shaft. The drive assembly comprises a motor, a brake, a cylindrical housing, and a control that controls the operation of the motor and in particular of the brake.The motor and the brake are held within the cylindrical housing by a press fit connection. The brake is located axially between the motor and the control. The motor is electrically connected to the control by a motor contacting, which passes axially through the brake. The motor contacting comprises at least one motor contacting plug and at least one motor contacting socket connected to each other.In a further embodiments, one of the motor contacting plugs and sockets is attached to the housing of the motor, and one of the motor contacting plugs and sockets (the other on of the above) is attached to the housing of the control. During assembly, the motor plug and socket attached to the control and motor unit can simply be connected, without the need to have intermediate connector in between. In particular one of the motor contacting plugs and sockets attached to the motor housing is plugged together with one of the motor contacting sockets and plugs attached to the control.In an embodiment, the motor contacting plugs bridge an axial extension of the brake. In other words, in particular the contacting plugs extend over a distance between the motor unit and the control, which is occupied by the brake.In an embodiment the brake housing has at least one plug receptacle through which the motor contacting plugs extend.The motor contacting plugs are in particular formed as straight rods extending from the motor to the control. This enables a simple assembly, since the rods keep their shape and position during the assembly process, which enables an easy connecting step. In particular the plug receptacle is formed as a straight hole, so that the brake can be slipped over the straight rods.In an embodiment a first motor contacting plug and socket connect the brake with the motor, and a second motor contacting plug and socket connect the brake with the control. The motor contacting plugs and sockets are oriented in a manner that the motor contacting is established and / or disestablished by a relative movement in the axial direction of the motor over the brake and / or control, and / or of the control over the motor and / or the brake. Here the brake unit serves as an intermediate contact between the motor unit and the control.The inventive method involves the steps of providing a motor having a motor housing, providing the brake having a brake housing, and providing the control. Initially, the brake, motor, and control are held separate from each other. The brake housing is arranged axially between the motor housing and the control. The motor contacting between the control and the motor is established by moving the brake housing, the motor housing, and the control towards each other.The invention provides in particular one or more of the following advantages.Simplified Assembly: The inventive roller allows for an easy way of assembling. By assembling the brake, the control, and the motor to each other, the electrical connections between the components can be realized automatically in particular eliminating the need for complex laying of flexible cables.Compact Design: The motor and the brake are held within a cylindrical housing in particular by a press fit connection. This compact design ensures that all components are securely housed within a narrow space, optimizing the use of space within the roller. In particular no flexible cables need to be located in a radial outward position.Efficient Electrical Connections: The motor contacting, which comprises motor contacting plugs and sockets, passes axially through the brake. This design ensures efficient and reliable electrical connections between the motor and the control, enhancing the overall performance of the roller.Reduced Maintenance: The use of straight rods for the motor contacting plugs, which extend from the motor to the control, simplifies the assembly process. The brake can be easily slipped over the straight rods, ensuring a secure and stable connection.Versatile Configuration: The roller can be configured in various embodiments, allowing for flexibility in design and application. For example, the brake housing can have plug receptacles that accommodate different types of motor contacting plugs and sockets, providing versatility in the possible combination of selectable components.Brief description of the drawingsAn example embodiment of the invention is described in more detail with the help of the figures; herein show fig. 1 a conventional conveyor zone in perspective view; fig. 2 a longitudinal section of an inventive motorized brake roller of the conveyor zone of figure 1 ; fig. 3 isolated a motor housing and a brake housing of the roller according to figure 2 in axial view; fig. 4 an exploded side view of a brake housing, a motor housing, a control and a cylindrical housing of the roller according to figure 2;fig. 5 a side view of the components according to figure 4 in a mounted state; fig. 6 an exploded side view of the components of figure 4 in an alternative embodiment; fig. 7 an exploded side view of the components of figure 4 in an alternative embodiment, fig. 8 an exploded side view of the components of figure 4 in an alternative embodiment.Detailed description of the inventionFigure 1 shows an exemplary conveyor zone 90, comprising several conveyor rollers at least one of which is a motorized roller 1 . The rollers are attached to a common frame 91 . An object 99 is linearly conveyed from an inlet i to an outlet o along a conveying direction d.By means of a presence sensor 95, the presence of a conveyed object 99 arranged on the conveyor zone 90 can be determined. The presence sensor 95 thereby generates a sensor signal, which is connected via a signal line (not shown) to a zone controller (not shown).Figure 2 shows a section of an inventive motorized roller 1 . The roller 1 has a roller tube 5, which is held rotatably around two axle shaft 4 by means of bearings 3. The roller tube provides a contact surface 51 for said object 99. On each end of the roller tube an endcap 2 is provided. The axis of the roller tube 5 and the axle shaft 4 define an axial direction a.A main cable 7 comprising a plurality of cable strands 71 is guided from outside through one of the axle shafts 4, which provides electrical power and data to the interior of the motorized roller 1.The axle shaft 4 is split into two separate shaft ends, each on one of the ends of the roller 1. The axle shaft is held rotationally fixed over the frame 91 .The roller 1 comprises an internal drive assembly 10, which provides a drive power to the roller tube 5. The drive assembly 10 comprises a motor 13, which drives a motor shaft S1 . The motor shaft S1 is connected to a gear 14, which connects the motor shaft S1 to a gear output shaft S2, so that the rotational speed of the gear output shaft S2 is reduced compared to the rotational speed of the motor shaft S1.The motor 13 and the gear 14 are located within a cylindrical housing 15. The cylindrical housing 15 is separate to the roller tube 5.The gear output shaft S2 is connected to a clutch 6, which provides a rotational fixed connection to the roller tube 5. A rotational movement of the gear output shaft causes a rotational movement of the roller tube.There may be embodiments without a gear. In this case, the motor shaft S1 may be coupled directly to the cutch 6.The brake 12 interacts with the motor shaft S1 , meaning that the brake 12 can selectively provide a braking force to the motor shaft S1 .Just for reference: In an alternative embodiment not covered by the present invention, the brake is in interaction with the gear output shaft. The gear output shaft is rotating with a lower rotational speed than the motor shaft. Consequently a brake interacting with the gear output shaft needs to provide a larger brake force. Compared to this aforementioned, a smaller brake can be used, if the brake interacts with the faster rotating motor shaft as in the present invention.The drive assembly 10 comprises a control 11 , which is also located within the cylindrical housing 15. Cable strands 71 of the main cable 7 are connected to the control 11 .The motor 13 is electrically connected to the control 11 by a motor contacting M. The brake 12 is electrically connected to the control 11 by a brake contacting B. The motor contacting M and the brake contacting B are located within the cylindrical housing 15.In particular the motor 13 is a three phase synchronous motor requiring the individual three contacts for each phase.The brake 12 and the motor 13 are assembled within the cylindrical housing 15 by a press fit.The brake 12 is located axially between the control 11 and the motor 13. Therefore the motor contacting M has to axially pass the brake 12 within the cylindrical housing 15.In a similar situation EP 4 175 129 A1 proposes, that the motor contacting is formed by a flexible wiring, which axially passes the brake in a radial groove of a housing of the brake. The groove extending in the axial direction in an outer portion of the brake housing (see EP 4 175 129 A1 , figure 6 in particular reference signs 55 and 57). Here the wiring between the control and the motor is connected as long as the components are outside of the cylindrical housing.The invention proposes another solution.Figures 3 and 4 show more details of components of the motorized brake roller 1 according to figure 2, in particular a motor housing 13H of the motor 13 and a brake housing 12H of the brake 12.The motor contacting M comprises a plurality of motor contacting plugs MPO attached to the motor housing 13H and projecting in axial direction towards the brake housing 12H and the control 11. The motor contacting plugs MPO are in particular formed as straight rods. The motor contacting M comprises a plurality of motor contacting sockets MSO attached to the control 11 and facing in axial direction towards the brake housing 12H and motor housing 13H. In the mounted state the motor contacting sockets MSO contact the motor contacting plugs MPO to provide an electrical connection between the control 11 and the motor 13.The brake housing 12H has a plurality of plug receptables 12R, each constituting through openings through the brake housing 12H extending over the entire axial length 12X of the brake housing 12H. The plug receptables 12R are in particular formed as straight holes, penetrating the brake housing 12H in a straight line. The plug receptables 12R are located in frontal view relative to the brake housing 12H in the same position as the contacting plugs MPO are located in frontal view relative to the motor housing 13H.For mounting the brake housing 12H and the motor housing 13H are relatively moved towards each other in axial direction, in particular during a press fit mounting step. Since the motor contacting plugs MPO are aligned with the plug receptables 12R, the motor contacting plugs MPO protrudes through the brake housing 12H and can contact the motor contacting socket MSO of the control 11 . The brake can simply be slipped over the straight rods, so that the motor contacting plugs MPO can penetrate through the plug receptables 12R.The plugin process is thereby effected automatically by moving the motor housing 13H, the brake housing 12H and the control 11 towards each other. At the same time, the motor 13, the brake 12 and the control 11 can be inserted into the cylindrical housing 15 by a press fit.During mounting no fumbling of flexible cables is required anymore.In figure 5, the components shown in figure 4 are in a mounted condition. The motor contacting plugs MPO contacting the motor contacting sockets MSO. The motor contacting plugs MPO thereby bridge an axial extension 12X of the brake 12, including the brake housing 12H.The motor contacting plugs MP may comprise isolations over the motor housing 13H (not shown). In addition there may be provided an assembling aid, ensuring proper introduction of the plugs into the receptables 12R.The contacting of the brake 12 to the controller 11 can be done in a similar way with the help of brake contacting plugs BP extending from the brake housing 12H towards the controller 11 . In the mounted state the contacting plugs BP contact brake contact sockets at the control 11 . This is merely illustrated in figures in figures 4 and 5 but applies also for the remaining embodiments.Figure 6 shows an alternative embodiment of the components shown in figure 4, which are used in an inventive roller according to figure 2. Here merely the differences to the embodiment of figure 4 are described.The brake housing 12H has first motor contacting sockets MS1 facing the motor housing 13H and - in the mounted condition - contacting the first motor contacting plugs MP1 , which are attached to the motor housing 13H. The first motor contacting plugs MP1 are shorter than the motor contacting plugs of figure 4, since they do not protrude through the brake housing 12H.In addition, attached to the brake housing 12H there are second motor contacting plugs MP2 separate to the first motor contacting plugs MP1 . The second motor contacting plugs MP2 contacting second motor contact sockets MS2 attached to the control 11 .Figure 7 shows an alternative embodiment of components shown in figure 4, which are used in an inventive roller according to figure 2. Here merely the differences to the embodiment of figure 4 are described.Attached to the brake housing 12H there are first motor contacting plugs MP1 protruding from the housing towards the motor housing 13H. Attached to the motor housing 13H there are first motor contacting sockets MS1 . In the mounted condition the first motor contacting sockets MS1 are in contact with the first motor contacting plugs MP1 .Attached to the brake housing 12H there are second motor contacting plugs MP2 protruding from the housing towards the control 11 . Attached to the control 11 there are second motor contacting sockets MS2. In the mounted condition the second motor contacting sockets MS2 are in contact with the second motor contacting plugs MP2.Each of the first motor contacting plugs MP1 is electrically connected at the brake 12H housing with one respective second motor contacting plug MP2 by a motor intermediate contact Ml, which may by a preassembled wire.Figure 8 shows a variation of the embodiment of components shown in figure 7. Here each of the first motor contacting plugs MP1 are made integral with one respective second motor contacting plug MP2. The separate motor intermediate contact Ml of figure 7 is obsolete.ln all the aforementioned embodiments the plugs can be formed by simple metal pins, having a sufficient form stability required for the plugging process.The embodiments of figure 6 to 8 have the same effect during assembly as the embodiments of figures 3 to 5. In a mounting step, the motor housing 13H, the brake housing 12H and the control 11 are moved towards each other. Thereby automatically the motor contacting plugs MPO, MP1 , MP2 contact the respective motor contacting sockets MSO, MS1 , MS2.List of reference signs1 motorized conveyor roller2 end cap3 end cap4 axle shaft5 roller tube51 support surface6 clutch7 main cable71 strand10 drive assembly11 control12 brake12R plug receptable12 brake housing13 motor13H motor housing14 drive gear15 cylindrical housingS1 motor shaftS2 gear output shaftM motor contactingMP motor contacting plugMS motor contacting socketMl motor intermediate connectionB brake contactingBP brake contacting plugBS brake contacting socket90 conveyor zone91 frame95 presence sensor99 object20:d conveying direction i inlet o outlet a axal direction-10-20:

Claims

Claims1. Motorized conveyor roller (1), comprising: a roller tube (5), in particular wherein the roller tube (5) provides a support surface (51) for an object to be conveyed (99); an axle shaft (4), a drive assembly (10), the drive assembly (10) is adapted to provide a drive force to the roller tube (5), powering a rotational movement of the roller tube (5) over the axle shaft (4); the drive assembly (10) comprises:- a motor (13)- a brake (12),- a cylindrical housing (15),- a control (11), adapted to control operation of the motor (13), wherein the motor (13) and the brake (12) are held within the cylindrical housing (15) in particular by a press fit connection, wherein the brake (12) is located axially between the motor (13) and the control (11), wherein the motor (13) is electrically connected to the control (11) by a motor contacting (M), wherein the motor contacting (M) is axially passing the brake (12); characterized in that the motor contacting (M) comprises at least one motor contacting plug (MP) and at least one motor contacting socket (MS) connected to each other.

2. Roller (1) according to the preceding claim, characterized in that one of the motor contacting plugs and sockets (MP, MS) is attached at a housing (13H) of the motor (13), and that one of the motor contacting plugs and sockets (MP, MS) is attached at a housing (11H) of the control (11).

3. Roller (1) according to the preceding claim, characterized in that one of the motor contacting plugs and sockets (MPO, MSO) attached to the motor housing (13H) is plugged together with one of the motor contacting sockets and plugs (MSO, MPO) attached to the control (11).

4. Roller (1) according to any of the preceding claims, characterized in that the motor connection plugs (MP) are bridging an axial extension (12X) of the brake (12).

5. Roller (1) according to any of the preceding claims, characterized in that the brake (12) has a brake housing (12H), the brake housing (12H) comprising at least one plug receptable (12R), wherein the motor connection plugs (MP) extending through the plug receptable (12R).

6. Roller (1) according to any of the preceding claims, characterized in that the motor connection plugs (MP) are formed as straight rods, the straight rods extending from the motor (13) to the control (11).

7. Roller (1) according to the preceding claim and claim 5, characterized in that the plug receptable (12R) is formed as a straight hole, so that the brake can be slipped over the straight rods.

8. Roller (1) according to any of claims 1 or 2, characterized in that a first of the motor contacting plug and socket (MP1 , MS1) is connecting the brake (12) with the motor (13), and that that a second of the motor contacting plug and socket (MP2, MS2) is connecting the brake (12) with the control (11).

9. Roller (1) according to any of the preceding claims, characterized in that the motor contacting plugs and sockets (MP, MS) are oriented in a manner, that the motor contacting (M) is established and / or disestablished by a relativemovement in the axial direction (a)- of the motor (13) over the brake (12) and / or control (11), and / or- of the control (11) over the motor (13) and / or the brake (12);10. Method of assembling a roller according to any of the preceding claims, comprising the steps of: providing the motor (13) having a motor housing (13H), providing the brake (12) having brake housing (12H), providing the control (11); wherein initially the brake, and motor and the control are held separate to each other; arranging the brake housing (12H) axially between the motor housing (13H) and the control (11), establishing the motor contacting (M) between the control (11) and the motor (13) by moving the brake housing (12H), the motor housing (13H) and the control (11) towards each other.- 13 -

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