Roller device and material conveying method

Abstract

Provided is a roller device (1) provided in a conveyance mechanism for conveying a material related to a sanitary article in a conveyance direction, the roller device (1) comprising: an attachment support (10) attached to a vertical wall (PL); a support part (20) provided at the distal end of the attachment support (10); a drive part (40) for rotationally driving the roller device (1), the drive part (40) being supported by the support part (20) on an output shaft (42, 32) side of the drive part (40); and a cylindrical part (100) rotatably attached to the output shafts (42, 32) and accommodating at least a part of the drive part (40) in a space on the inner peripheral side. The support part (20) is positioned in the central part in the axial direction of the cylindrical part (100).

Description

Roller device and material transport method

[0001] The present invention relates to a roller device and a material transport method.

[0002] Conventionally, roller devices such as conveying rollers that are driven to rotate and convey materials for sanitary articles in a conveying direction have been known in manufacturing equipment for producing diapers and other sanitary articles. For example, Patent Document 1 discloses a technology relating to a motor roller (roller device) that includes a pipe 110 that is rotatably held by mounting shafts 150 and 152 at both ends and that is rotated by a motor M.

[0003] Japanese Patent Application Publication No. 11-127556

[0004] In the roller device of Patent Document 1, the roller unit (pipe 110) is supported at two or more locations (mounting shafts 150, 152), thereby enhancing stability during rotational driving. However, problems arose, such as the need to provide support members on both sides to support both ends of the roller device, making the mounting structure complicated and requiring a large amount of space. On the other hand, if the roller device were to have a simple mounting structure with a cantilever support structure, the roller unit would be more likely to bend due to the load acting on it, which could result in insufficient stability during rotational driving of the roller device.

[0005] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a roller device that has a simple mounting structure and is highly stable.

[0006] The main invention for achieving the above object is a roller device provided in a conveying mechanism for conveying materials related to sanitary products in a conveying direction, the roller device comprising: a mounting support attached to a vertical wall portion; a support portion provided at the tip of the mounting support portion; a drive portion for rotating the roller device, the drive portion having an output shaft side supported by the support portion; and a cylindrical portion rotatably attached to the output shaft and accommodating at least a portion of the drive portion in a space on its inner periphery, the support portion being located at the center in the axial direction of the cylindrical portion. Other features of the present invention will become apparent from the description of this specification and the accompanying drawings.

[0007] According to the present invention, it is possible to provide a roller device having a simple mounting structure and high stability.

[0008] 4A is a perspective view showing the overall configuration of a roller device 1 according to a first embodiment. FIG. 4B is a perspective view showing the overall configuration of a roller device 1 according to a third embodiment. FIG. 4B is a perspective view showing the overall configuration of a roller device 1 according to a third embodiment. FIG. 4B is a perspective view showing the overall configuration of a roller device 2 according to a third embodiment. FIG. 4B is a perspective view showing the overall configuration of a roller device 2 according to a third embodiment. FIG. 4B is a perspective view showing the overall configuration of a roller device 2 according to a third embodiment. FIG. 4B is a perspective view showing the overall configuration of a roller device 2 according to a fourth ...

[0009] At least the following matters will become clear from the description of this specification and the accompanying drawings.

[0010] (Aspect 1) A roller device provided in a conveying mechanism for conveying materials related to sanitary products in a conveying direction, the roller device comprising: a mounting support attached to a vertical wall; a support portion provided at the tip of the mounting support; a drive portion that rotates the roller device, the drive portion having an output shaft side supported by the support portion; and a cylindrical portion that is rotatably attached to the output shaft and that houses at least a portion of the drive portion in a space on its inner periphery, the support portion being located at the center in the axial direction of the cylindrical portion.

[0011] According to the roller device of Aspect 1, a load acts on the mounting support and the support portion, but a load is unlikely to be applied to the drive portion, and a large moment is unlikely to act, making it easy to perform stable rotational operation (conveying operation). Furthermore, since the mounting support is attached to the vertical wall portion on the other axial side and one axial side is open, the mounting structure can be simplified. Furthermore, since the cylindrical portion is supported at the center in the axial direction, tilting of the cylindrical portion is suppressed, resulting in more stable conveying operation.

[0012] (Aspect 2) The roller device according to aspect 1, wherein the cylindrical portion is supported only by a hub attached to the output shaft.

[0013] According to the roller device of aspect 2, the position at which the load is received by the hub is fixed to one point in the center of the cylindrical portion in the axial direction, so that the center of the cylindrical portion is prevented from being significantly deflected by the load acting on the cylindrical portion, making it easier to achieve more stable conveying operations.

[0014] (Aspect 3) The roller device according to Aspect 1 or 2, wherein the cylindrical portion has a tube portion and a protrusion protruding from the inner periphery of the tube portion, and the hub has a mating portion that mates with the protrusion portion and a ring portion having an outer diameter larger than that of the mating portion, and the outer diameter of the ring portion is smaller than the inner diameter of the tube portion.

[0015] According to the roller device of Aspect 3, when the hub is inserted into the space on the inner periphery of the cylindrical portion and fastened to the cylindrical portion, the inner periphery of the cylindrical portion and the outer periphery of the hub are less likely to interfere with each other, so the operation of connecting the output shaft and the cylindrical portion via the hub can be performed accurately and smoothly.

[0016] (Aspect 4) The roller device according to any one of Aspects 1 to 3, wherein the hub has an air vent that allows air to pass from one side to the other side in the axial direction.

[0017] According to the roller device of Aspect 4, the entire cylindrical portion is ensured to be breathable from one end to the other end in the axial direction, and heat emitted from the drive unit is prevented from being trapped in the space on the inner periphery of the cylindrical portion. This improves heat dissipation and facilitates more stable conveying operations.

[0018] (Aspect 5) The roller device according to any one of Aspects 1 to 4, wherein the drive unit is supported by the support unit via a reducer.

[0019] According to the roller device of Aspect 5, by configuring the drive unit to be supported by the support unit via a highly rigid reducer, the support state of the drive unit is more likely to be stable compared to when the drive unit is directly supported by the support unit, making it easier to perform stable conveying operations. Furthermore, by providing a reducer, it becomes easier to appropriately adjust the rotational speed and torque output by the drive unit.

[0020] (Aspect 6) The roller device according to any one of Aspects 1 to 5, wherein the reducer is a planetary reducer, and the reduction ratio of the reducer is 1 / 3 to 1 / 5.

[0021] According to the roller device of Aspect 6, a suitable conveying speed can be easily achieved by rotating the cylindrical portion at a rotational speed of about 1 / 3 to 1 / 5 of the rated output of the drive unit, and therefore, the conveying operation can be performed efficiently while the drive unit is operating at its rated speed.

[0022] (Aspect 7) The roller device according to any one of Aspects 1 to 6, wherein the roller device does not have a portion that protrudes across the vertical wall portion on the side opposite to the side on which the mounting post is attached.

[0023] The roller device of Aspect 7 is easy to install because the installation can be completed on only one side of the vertical wall in the axial direction. Furthermore, because no parts protrude onto the opposite side of the vertical wall, they do not interfere with the installation of other parts or devices on the opposite side, which increases the degree of freedom in the layout design of the entire device, including the conveying mechanism.

[0024] (Aspect 8) The roller device according to any one of Aspects 1 to 7, wherein the mounting support is provided along the axial direction and is not disposed in at least one of the positions above the drive unit, below the drive unit, upstream of the drive unit in the conveying direction, and downstream of the drive unit in the conveying direction.

[0025] According to the roller device of Aspect 8, heat released from the drive unit is less likely to be trapped in areas where no mounting posts are provided, thereby improving heat dissipation. Also, it becomes easier to secure space for installing various cables connected to the drive unit, and the cables can be arranged without being interfered with by the mounting posts.

[0026] (Aspect 9) The roller device according to any one of Aspects 1 to 8, wherein the mounting posts are arranged at three locations among above the drive unit, below the drive unit, upstream of the drive unit in the conveying direction, and downstream of the drive unit in the conveying direction.

[0027] According to the roller device of Aspect 9, by providing the mounting posts in three locations, the support part is supported by the three mounting posts in a tripod-like manner, thereby ensuring installation space for the cable, improving heat dissipation, and supporting the support part more stably and firmly.

[0028] (Aspect 10) The roller device according to any one of Aspects 1 to 9, which constitutes a nip roll type conveying mechanism that conveys the material in the conveying direction while sandwiching and pressurizing the material between a nip roll having a rotation axis parallel to the rotation axis of the roller device.

[0029] According to the roller device of Aspect 10, the nip pressure applied by the nip roll is likely to be uniformly applied to the entire axial direction of the cylindrical portion of the roller device. Therefore, gaps are unlikely to occur where the nip roll and the cylindrical portion face each other, making it easier to stabilize the conveying operation. Furthermore, the uniform application of nip pressure makes it easier to prevent wrinkles from forming on the conveyed medium (material) and flapping due to speed fluctuations.

[0030] (Aspect 11) The roller device according to any one of Aspects 1 to 10, which constitutes a belt conveyor type transport mechanism that transports the material placed on a ring-shaped belt in the transport direction by rotating the belt.

[0031] According to the roller device of Aspect 11, stable conveyance can be achieved by driving the conveyor belt using a roller device that can rotate without distortion or tilt. In addition, the cylindrical portion of the highly stable roller device makes it easy to adjust the belt tension to a constant level, thereby achieving stable conveyance with little loss.

[0032] (Aspect 12) A material conveying method for conveying materials related to sanitary products in a conveying direction using a conveying mechanism equipped with a roller device, wherein the roller device has a mounting support attached to a vertical wall portion, a support portion provided at a tip of the mounting support, a drive portion that rotates the roller device, the drive portion having an output shaft side supported by the support portion, and a cylindrical portion rotatably attached to the output shaft and accommodating at least a portion of the drive portion in a space on its inner periphery, and the support portion is located at a center portion in the axial direction of the cylindrical portion.

[0033] According to the material conveying method of Aspect 12, a load acts on the mounting posts and support parts of the roller device, but the drive unit and reducer are less likely to be loaded and a large moment is less likely to act on them. Therefore, the position of the output shaft is less likely to deviate from the central axis of the roller device, making it easier to perform stable conveying operations. Furthermore, because the cylindrical part is supported at the center in the axial direction, conveying is performed with the cylindrical part less likely to tilt, resulting in more stable conveying operations.

[0034] First Embodiment As a roller device according to a first embodiment, a roller device 1 constituting a conveying mechanism for conveying materials related to hygiene products such as disposable diapers and sanitary napkins will be described.

[0035] <Basic Configuration of Roller Device 1> FIG. 1 is a perspective view showing the overall configuration of the roller device 1 according to the first embodiment. FIG. 2 is a perspective view showing the cross-sectional configuration of the roller device 1 in the state shown in FIG. 1. FIG. 3 is a cross-sectional view taken along the line A-A in FIG. 2. In FIGS. 1 to 3, the vertical direction, the conveying direction, and the axial direction are defined as being orthogonal to one another. The conveying direction is the direction in which materials are conveyed, and the axial direction is the direction along the rotation axis CA (the central axis of the roller device 1) when the roller device 1 rotates in the direction of the arrow in FIG. 1 (or the opposite direction). For the sake of explanation, FIG. 1 shows the cylindrical portion 100 as transparent, allowing the space inside (the inner circumferential side) of the cylindrical portion 100 to be seen through the cylindrical portion 100.

[0036] The roller device 1 has a mounting support 10, a support portion 20, a reducer 30, a drive portion 40, a hub 50, a shaft fastening portion 60, and a cylindrical portion 100. The roller device 1 is fixed to a vertical wall portion PL (corresponding to a so-called end plate) that stands vertically (in the up-down direction in FIG. 1 ) from a horizontal plane such as the ground or a base frame.

[0037] The mounting posts 10 are plate-shaped members for attaching the roller device 1 to the vertical wall portion PL and are formed of metal plates having a predetermined length. In the first embodiment, multiple mounting posts 10 are provided along the axial direction. Specifically, three mounting posts 10 are provided: an upstream transport post 11 provided upstream of the drive unit 40 in the transport direction; a downstream transport post 12 provided downstream of the drive unit 40 in the transport direction; and a lower post 13 provided vertically below the drive unit 40. Each of the posts 11 to 13 is joined and fixed to a plate-shaped fixing plate 15 on the other side in the axial direction and is attached to the vertical wall portion PL via the fixing plate 15. However, the mounting posts 10 (posts 11 to 13) may also be attached directly to the vertical wall portion PL without the fixing plate 15.

[0038] The support part 20 is provided at one axial end (tip) of the mounting support 10 (supports 11 to 13), and is a part that supports the drive part 40 and the reducer 30. The support part 20 is a disk-shaped member that is placed in the space on the inner periphery side of the cylindrical part 100, and has a fixing hole 21 of a predetermined size in the radial center (see FIG. 3). The fixing hole 21 is a slot for fixing and supporting the reducer 30 or the drive part 40.

[0039] The reducer 30 is a device for adjusting the rotation speed of the output shaft 42 of the drive unit 40, and in the first embodiment, a known planetary reducer is used. The reducer 30 has a housing 31, an input shaft (not shown), and an output shaft 32 coaxial with the input shaft. An internal gear, multiple planetary gears, a planet carrier, etc. (none of which are shown) are provided inside the housing 31, but since the structure and function of the planetary reducer itself are known, a detailed description thereof will be omitted.

[0040] At least a portion of the housing 31 of the reducer 30 is fitted into the fixing hole 21 of the support part 20, so that the side (one axial side) where the output shaft 32 of the reducer 30 is provided is supported by the support part 20 (see FIGS. 2 and 3). At this time, the reducer 30 is supported so that the axial centers of the input shaft and output shaft 32 of the reducer 30 overlap with the central axis (rotation axis) CA of the roller device 1. The input shaft of the reducer 30 is connected to the output shaft 42 of the drive part 40, which will be described later, and the rotational speed (number of rotations) input from the output shaft 42 to the input shaft of the reducer 30 is reduced and output from the output shaft 32.

[0041] The drive unit 40 is a motor that generates power to rotate the roller device 1, and has a housing 41 and an output shaft 42. The housing 41 of the drive unit 40 can be connected to the housing 31 of the reducer 30 (see FIGS. 2 and 3 ). When the two are connected, the output shaft 42 of the drive unit 40 and the input shaft of the reducer 30 are connected with their axes aligned, and the rotation output by the drive unit 40 is input to the reducer 30. In other words, in the first embodiment, the drive unit 40 is supported by the support unit 20 via the reducer 30.

[0042] However, the reducer 30 does not necessarily have to be provided. For example, if there is no need to adjust the rotational speed or torque of the rotation output by the drive unit 40, the drive unit 40 may be directly supported by the support unit 20 without the reducer 30 (see the second embodiment). In the following, when a description is given of the output shaft 32 of the reducer 30, the description also applies to the output shaft 42 of the drive unit 40.

[0043] When the output shaft side of the drive unit 40 is supported by the support unit 20 via the reducer 30, as shown in FIGS. 2 and 3 , at least a portion of the drive unit 40 is housed in the space on the inner periphery of the cylindrical portion 100. This allows the roller device 1 to be configured more compactly (mainly in terms of length in the axial direction) than when the entire drive unit 40 is disposed protruding outside the cylindrical portion 100. Furthermore, a connection port 45 is provided on the upper side of the housing 41 in the vertical direction and on the other axial side to connect a control cable for controlling the drive unit 40 and a power cable for supplying power. In FIG. 3 , the connection port 45 is exposed outside the space on the inner periphery of the cylindrical portion 100 (on the other axial side). This makes it easier to prevent accidents, such as a cable connected to the connection port 45 coming into contact with the cylindrical portion 100 and breaking during rotation of the roller device 1 (cylindrical portion 100).

[0044] The hub 50 is a generally flange-shaped member that is attached to the output shaft 32 of the reducer 30 or the output shaft 42 of the drive unit 40 and supports the cylindrical portion 100. The hub 50 has a cylindrical insertion portion 51 that is inserted into the output shaft 32 (output shaft 42) for attachment, and a flange portion 52 for connecting the cylindrical portion 100. The inner diameter of the insertion portion 51 is slightly larger than the outer diameter of the output shaft 32 (output shaft 42), and a shaft fastening portion 60, which will be described later, is used to attach and secure the hub 50 to the output shaft 32 (output shaft 42).

[0045] The flange portion 52 has a mating portion 521 for mating with the protrusion 102 (see FIG. 3) protruding toward the inner periphery of the cylindrical portion 100, and a ring portion 522 having an outer diameter larger than that of the mating portion 521. The ring portion 522 is provided with a plurality of bolt holes 54, 54... at equal intervals along the circumferential direction for inserting fastening bolts to fasten the ring portion 522 to the protrusion 102. In addition, a plurality of ventilation holes 55, 55... are provided at equal intervals along the circumferential direction by penetrating the ring portion 522 in the axial direction to ensure ventilation in the axial direction.

[0046] The shaft fastening portion 60 is inserted between the output shaft 32 (output shaft 42) of the reducer 30 and the flange portion 52 of the hub 50, and is a portion that uses friction to secure the output shaft 32 (output shaft 42) and the hub 50 together. In this embodiment, the shaft fastening portion 60 elastically deforms radially outward and inward, thereby eliminating the gap between the output shaft 32 (output shaft 42) and the shaft fastening portion 60 and the gap between the hub 50 and the shaft fastening portion 60, generating a large frictional force at the contact points. Use of such a shaft fastening portion 60 eliminates the need for keyway machining or the like, allowing the hub 50 to be easily and stably attached to the output shaft 32 (output shaft 42). Furthermore, use of the shaft fastening portion 60 makes it easy to align the rotational axes of the hub 50 and the output shaft 32 (output shaft 42) with the center axis (rotational axis) CA of the roller device 1.

[0047] The cylindrical portion 100 is a hollow pipe-shaped member and includes a tube portion 101 and a protrusion portion 102 that protrudes from the inner periphery of the tube portion 101. The tube portion 101 rotates about a central axis (rotation axis) CA to convey a medium (e.g., sanitary goods) placed on the outer periphery of the tube portion 101 in a conveyance direction that intersects with the central axis (rotation axis) CA (see FIG. 1 ). The protrusion portion 102 is a portion for attaching the cylindrical portion 100 to the hub 50. As shown in FIG. 3 , the tip of the protrusion portion 102 engages with a mating portion 521 of the hub 50 and is fastened to a ring portion 522 by a fastening bolt. As a result, the cylindrical portion 100 is attached to the output shaft 32 of the reducer 30 (the output shaft 42 of the drive unit 40) via the hub 50 in a state where it cannot rotate relative to the output shaft 32.

[0048] <Regarding the conveying operation using the roller device 1> In the roller device 1, the medium to be conveyed can be conveyed in the conveying direction by rotating the cylindrical portion 100, which is attached so as to be coaxial with the output shaft 32 of the reducer 30 (output shaft 42 of the drive unit 40), based on the rotational force output by the drive unit 40.

[0049] Conventionally, roller devices used to transport transported media (materials) have often been designed so that the rollers are supported at both axial ends to ensure stable rotation. In such cases, it is necessary to provide support frames or bases on both axial ends, which makes installation on vertical walls (end plates) complicated and requires a large installation space, reducing the flexibility of the overall device layout.

[0050] On the other hand, if the roller device is supported on only one side of the axial direction (i.e., if a cantilever support structure is used), the load acting on the roller section is likely to cause the entire roller device to bend, which could result in insufficient stability during conveying operations.

[0051] In contrast, the roller device 1 of this embodiment is supported from one side in the axial direction, which simplifies the mounting structure, and by appropriately adjusting the support method, stable conveying operation can be achieved.

[0052] Specifically, in the roller device 1, the entire load is supported by the mounting support 10 attached to the vertical wall portion PL and the support portion 20 provided at the tip (one axial side) of the mounting support 10. In other words, the load of the roller device 1 itself and the load of the transported medium (material) received by the cylindrical portion 100 are supported by the highly rigid mounting support 10 and support portion 20, so that the drive portion 40 and the reducer 30 are unlikely to be subjected to extremely large loads or moments.

[0053] If the mounting column 10 and support portion 20 were not provided and the drive unit 40 and reducer 30 were directly attached to the vertical wall portion PL at the other axial end, a large moment would be likely to be generated in the drive unit 40 and reducer 30. In other words, if the drive unit 40 and reducer 30 were in a cantilevered state and served as structural members bearing the load of the entire device and the load of the transported medium, the greater the load and the longer the axial distance from the vertical wall portion PL, the greater the moment acting on the drive unit 40 and reducer 30, causing them to bend. In this case, it would be difficult for the roller device 1 to perform stable rotational operation (transport operation).

[0054] The roller device 1 of this embodiment is configured so that loads act primarily on the mounting support 10 and the support portion 20, and is supported by the support portion 20. Furthermore, because the support portion 20 is located in the axial center of the cylindrical portion 100, loads are unlikely to be applied to the drive portion 40 and the reducer 30, and large moments are unlikely to act on them. Therefore, the positions of the output shaft 32 of the reducer 30 and the output shaft 42 of the drive portion 40 are unlikely to shift from the central axis (rotation axis) CA of the roller device 1, facilitating stable rotational operation (conveyance operation). Furthermore, the roller device 1 is attached to the vertical wall portion PL on the other axial side by the mounting support 10, while one axial side is open. In other words, there is no need to provide a support member or a panel corresponding to the vertical wall portion PL on one axial side, simplifying the mounting structure.

[0055] Furthermore, in the roller device 1, since the support unit 20 is located in the center of the cylindrical unit 100 in the axial direction, the load balance during conveyance is excellent and stable conveyance operations are easily performed. Note that the "center in the axial direction" of the cylindrical unit 100 refers to the central portion when the cylindrical unit 100 is divided into three equal parts in the axial direction. For example, in FIG. 3, when the length of the cylindrical unit 100 in the axial direction is L100, the support unit 20 is located in the central region of the region obtained by dividing L100 into three equal parts.

[0056] When transporting transported media (materials) using a transport roller such as the roller device 1, in order to prevent the load balance of the cylindrical portion 100 from being disrupted and causing the cylindrical portion 100 to rotate in a tilted state, or to prevent the transported media from meandering, transport is typically performed so that the center position of the transported media (materials) is aligned with the center position in the axial direction of the cylindrical portion 100. In other words, the center of gravity of the transported media (materials) is located near the center position in the axial direction of the cylindrical portion 100. In the roller device 1, the support portion 20 is disposed in the center of the axial direction of the cylindrical portion 100, so the support portion 20 is more likely to support the center of gravity of the transported media (materials). Therefore, compared to when the support position of the support portion 20 is significantly deviated from the center in the axial direction of the cylindrical portion 100, tilting of the cylindrical portion 100 is more likely to be prevented, and more stable transport operations can be performed.

[0057] Furthermore, in the roller device 1, the cylindrical portion 100 is supported only by the hub 50. In other words, the cylindrical portion 100 is supported by the hub 50 at one point in the axial direction. This results in a load balance with the position of the hub 50 at its apex, and the load center of the transported medium (material) is aligned with the position of the hub 50 in the axial direction, making it easier to achieve stable transport operations. FIG. 4A is a diagram illustrating the transport operation of a conventional roller device 5, as a comparative example, in which the rollers are supported on both sides in the axial direction. FIG. 4B is a diagram illustrating the transport operation of the roller device 1 according to this embodiment in which the rollers are supported at the center in the axial direction.

[0058] In the roller device 5 of the comparative example, support portions are provided at both axial ends, and the load of the cylindrical portion 100 is supported at both axial ends. When the load of the transported medium (material) acts on the cylindrical portion 100 in this state, the greater the distance from the support portions, the more likely the cylindrical portion 100 is to bend. As shown by the dotted line in FIG. 4A , the cylindrical portion 100 may bend more significantly at the axial center. Such bending may cause the transported medium (material) to wrinkle or meander during transport. In particular, bending in a nip roll-type transport mechanism (see FIG. 9 ), described below, may prevent uniform pressing between the nip roll and the cylindrical portion 100, potentially causing problems such as wrinkles and air entrapment in the transported medium (material).

[0059] In contrast, in the roller device 1 of this embodiment, as shown in FIG. 4B , the cylindrical portion 100 is supported only by the hub 50 located near the axial center. This makes bending less likely, and even if bending does occur, it is a small, upwardly convex bending as shown by the dotted line in FIG. 4B . This reduces the risk of wrinkles or meandering during conveyance of the conveyed medium (material), compared to a large, downwardly concave bending as shown in FIG. 4A . Therefore, more stable conveyance operations can be achieved. In particular, in a nip roll-type conveyance mechanism (see FIG. 9 ) described below, uniform pressing is more easily applied between the nip roll and the cylindrical portion 100, reducing problems such as wrinkles and air entrapment in the conveyed medium (material).

[0060] Furthermore, in the roller device 1 of the first embodiment, the drive unit 40 is supported by the support unit 20 via the reducer 30. Generally, planetary reducers such as the reducer 30 are designed to have sufficient strength to maintain the planetary gears inside the housing 31 while ensuring smooth movement. Therefore, the housing 31 of the reducer 30 is often at least more rigid than the housing 41 of the drive unit 40. Therefore, by configuring the support unit 20 to support the drive unit 40 via the highly rigid reducer 30, the stability of the drive unit 40 can be improved compared to when the drive unit 40 is directly supported. This facilitates stable conveyance operation. Furthermore, the provision of the reducer 30 makes it easier to appropriately adjust the rotational speed and torque output by the drive unit 40.

[0061] The speed reducer 30 provided in the roller device 1 preferably has a reduction ratio of 1 / 3 to 1 / 5. That is, it is preferable to use a planetary reducer whose rotational speed can be adjusted so that the value obtained by dividing the rotational speed output by the output shaft 32 of the reducer 30 by the rotational speed output by the output shaft 42 of the drive unit 40 falls within the range of 1 / 3 to 1 / 5. When the roller device 1 is used as a conveying mechanism such as a conveying roller, an appropriate conveying speed can be easily achieved by rotating the cylindrical portion 100 at a rotational speed of approximately 1 / 3 to 1 / 5 of the rated output of the drive unit 40 (e.g., rated rotational speed: 3000 rpm). Therefore, by using a reducer 30 with such a reduction ratio, the drive unit 40 can be operated at rated speed to efficiently perform the conveying operation.

[0062] It should be noted that the reducer 30 used in the roller device 1 is preferably a planetary reducer from the viewpoint of the load resistance relative to the dimensions of the device and the reduction ratio. Therefore, in the roller device 1 of the first embodiment, a planetary reducer is used as the reducer 30, rather than a Cyclo reducer (registered trademark) or other reducers.

[0063] The hub 50 is also provided with ventilation holes 55 that allow air to pass from one axial end to the other. This ensures ventilation between one axial end and the other axial end of the cylindrical portion 100 (roller device 1) as a whole, and prevents heat released from the drive unit 40 from being trapped in the space on the inner periphery of the cylindrical portion 100. This improves the heat dissipation of the roller device 1, making it easier to perform more stable conveyance operations.

[0064] Furthermore, the roller device 1 is attached to the vertical wall PL using the mounting support 10 (and the fixing plate 15), and during installation, no parts, such as mounting bolts, are provided on the other axial surface of the vertical wall PL. In other words, there is no part that protrudes from the vertical wall PL on the side opposite the side where the mounting support 10 is attached. With this configuration, installation is easy because the installation work can be completed on only one axial surface of the vertical wall PL. Furthermore, since there are no parts that protrude from the opposite surface of the vertical wall PL, they do not interfere with the installation of other parts or devices on the opposite surface, and this increases the flexibility of the layout design of the entire device, including the conveying mechanism.

[0065] Furthermore, the mounting support 10 is not provided in at least one of the following locations: above the drive unit 40, below the drive unit 40, upstream of the drive unit 40 in the conveying direction, and downstream of the drive unit 40 in the conveying direction. As described with reference to FIGS. 1 to 3 , the roller device 1 has mounting support 10 provided in three locations: the upstream support 11 on the upstream side in the conveying direction, the downstream support 12 on the downstream side in the conveying direction, and the lower support 13 on the lower side in the vertical direction. No mounting support 10 is provided above the drive unit 40. By providing at least one location in the space surrounding the drive unit 40 where no mounting support 10 is provided, heat emitted from the drive unit 40 is less likely to be trapped in the location where no mounting support 10 is provided, thereby improving heat dissipation. Furthermore, it is easier to secure space for installing various cables connected to the drive unit 40, and cables can be easily routed without interference from the mounting support 10.

[0066] If there is only one location in the space around the drive unit 40 (top, bottom, left, and right) where a mounting support 10 is not provided, then mounting supports 10 will be provided at three locations around the drive unit 40. By providing mounting supports 10 at three locations, the support unit 20 is supported by three mounting supports 10 in a tripod-like manner. Therefore, it is possible to secure cable installation space, improve heat dissipation, and support the support unit 20 more stably and firmly.

[0067] In this embodiment, the connection port 45 for connecting cables such as a power cable to the drive unit 40 is provided on the upper side of the drive unit 40, and no mounting support 10 is provided on the upper side. This configuration makes it easy to secure space above the drive unit 40 and facilitates cable installation and connection work. Alternatively, the drive unit 40 may be configured with the mounting support 10 provided on the upper side and no mounting support 10 provided on the lower side. In this case, the mounting support 10 provided on the upper side of the drive unit 40 can be used as a foothold when performing maintenance work, improving workability. Furthermore, ensuring a foothold for workers prevents accidental stepping on cables. Furthermore, it is easy to prevent paper dust, dirt, and the like from accumulating on the upper surface of the drive unit 40.

[0068] Furthermore, the flange portion 52 of the hub 50 provided in the roller device 1 has a ring portion 522 and a mating portion 521, and the outer diameter D522 of the ring portion 522 is larger than the outer diameter D521 of the mating portion 521 and smaller than the inner diameter d101 of the tube portion 101 of the cylindrical portion 100 (see FIG. 3 ). With this configuration, when the hub 50 is inserted into the space on the inner periphery of the cylindrical portion 100 and the ring portion 522 of the hub 50 is fastened to the protrusion 102 of the cylindrical portion 100, interference between the inner periphery of the cylindrical portion 100 and the outer periphery of the hub 50 is reduced. Therefore, the operation of connecting the output shaft 32 (42) and the cylindrical portion 100 via the hub 50 can be performed accurately and smoothly.

[0069] <Modifications> The size of each part of the roller device 1 can be changed as appropriate depending on the size of the material to be transported and the size of the space in which the device is installed. Fig. 5 is a perspective view showing a modification in which the axial length of the cylindrical part 100 is shortened. Fig. 6 is a perspective view showing a modification in which the axial length of the cylindrical part 100 is lengthened.

[0070] The modified roller device 1 shown in FIG. 5 includes a cylindrical portion 100a. The axial length L100a of the cylindrical portion 100a is shorter than the axial length L100 of the cylindrical portion 100 of the roller device 1 described in FIGS. 1 to 3 (L100a<L100). Therefore, it is suitable for transporting materials with a narrow axial width. When changing the length of the cylindrical portion 100a, the axial length of the mounting support 10 is also changed. The remaining components can be the same as those of the roller device 1 of the first embodiment. In other words, the modified roller device 1 shown in FIG. 5 can be achieved simply by replacing the cylindrical portion 100 and the mounting support 10 of the roller device 1.

[0071] Similarly, the modified roller device 1 shown in Fig. 6 includes a cylindrical portion 100b. The axial length L100b of the cylindrical portion 100b is longer than the axial length L100 of the cylindrical portion 100 of the roller device 1 described in Figs. 1 to 3 (L100b>L100). Therefore, it is suitable for transporting materials that are wide in the axial direction.

[0072] 5 and 6, the length of the mounting column 10 is adjusted so that the support portion 20 and the hub 50 are positioned at the center of the cylindrical portion 100a (100b) in the axial direction. This allows stable transportation to be achieved regardless of the length of the cylindrical portion 100a (100b).

[0073] Second Embodiment In the second embodiment, a roller device 2 not equipped with a reducer 30 will be described. Fig. 7 is a perspective view showing the overall configuration of the roller device 2 according to the second embodiment. Fig. 8 is a plan view showing the cross-sectional structure of the roller device 2, and corresponds to Fig. 3 of the first embodiment.

[0074] The roller device 2 of the second embodiment has a configuration substantially similar to that of the roller device 1 of the first embodiment, except that it does not include the reducer 30, and the configurations of the cylindrical portion 100, the hub 50 that supports the cylindrical portion 100, and other components are the same as those of the roller device 1. On the other hand, the roller device 2 differs from the roller device 1 in that the drive unit 40 is supported directly by the support unit 20 without the reducer 30, and the hub 50 is attached to the output shaft 42 of the drive unit 40 (see FIG. 8 ).

[0075] Even with the roller device 2 having this configuration, it is possible to achieve the same functions as the roller device 1 of the first embodiment. That is, because the weight of the roller device 2 and the load of the transported medium (material) are primarily supported by the mounting support 10 and the support portion 20, a large load is unlikely to act on the drive unit 40. Furthermore, because the support portion 20 and the hub 50 are located in the axial center of the cylindrical portion 100, deflection and tilt of the cylindrical portion 100 are suppressed, facilitating stable transport operations. Furthermore, because the roller device 2 is attached to the vertical wall portion PL on the other axial side and is open on one axial side, there is no need to provide a support member on one axial side or a panel corresponding to the vertical wall portion PL, thereby simplifying the mounting structure.

[0076] Third Embodiment In the third embodiment, a nip roll type transport mechanism 3 will be described, which transports a medium (material) in a transport direction by rotating two rolls while applying pressure to the medium by sandwiching the medium between them. Fig. 9 is a perspective view of the nip roll type transport mechanism 3 in the third embodiment. Fig. 10 is a schematic cross-sectional view of the transport mechanism 3 as viewed from the upstream side in the transport direction.

[0077] The transport mechanism 3 includes the roller device 1 described in the first embodiment and a nip roll device 200 having a rotation axis CA2 parallel to the rotation axis CA of the roller device 1. The roller device 1 is the same as in the first embodiment, and therefore a description thereof will be omitted. Note that it is also possible to configure a nip roll type transport mechanism 3 using the roller device 2 of the second embodiment instead of the roller device 1.

[0078] The nip roll device 200 includes a mounting support 210, a pressure unit 220, a support unit 230, and nip rolls 240. In FIGS. 9 and 10 , the nip roll device 200 is provided on the upper side of the roller device 1 in the vertical direction. The mounting support 210 is attached to the vertical wall portion PL on the other axial side and supports the pressure unit 220 on one axial side. The pressure unit 220 applies pressure to the nip roll 240 from the upper side to the lower side in the vertical direction and includes a piston portion 221. The piston portion 221 is driven by a pressure drive unit (not shown) and moves relatively in the vertical direction to apply pressure (nip pressure) to the cylindrical portion 100 of the roller device 1 located below the nip roll device 200. The support portion 230 is provided at the bottom of the piston portion 221 and supports the nip roll 240 rotatably around a rotation axis CA2.

[0079] Nip roll 240 is a cylindrical part, and is arranged so that the outer circumferential surface of nip roll 240 is in contact with the outer circumferential surface of cylindrical portion 100 of roller device 1. Then, by being pressed downward by pressure unit 220, nip roll 240 applies pressure (nip pressure) to cylindrical portion 100 and rotates in response to the rotation of cylindrical portion 100. Pressure is applied in a direction that brings rotation axis CA2 of nip roll 240 closer to rotation axis CA of roller device 1 (cylindrical portion 100), and by rotating while applying nip pressure with the medium to be conveyed (material) sandwiched between cylindrical portion 100 and nip roll 240, non-conveyed medium is conveyed in the rotation direction (conveying direction).

[0080] When such a nip roll-type conveying mechanism 3 is configured using the roller device 1, the nip pressure applied by the nip roll 240 tends to act uniformly over the entire axial direction of the cylindrical portion 100. As described in FIG. 4B , the cylindrical portion 100 of the roller device 1 is supported by the hub 50 at its center in the axial direction, and has a structure that tends to suppress bending or tilting due to load acting on the cylindrical portion 100. Therefore, gaps due to bending or tilting are unlikely to occur where the nip roll 240 and the cylindrical portion 100 face each other, and uniform nip pressure acts over the entire axial direction of the cylindrical portion 100, making it easier to stabilize the conveying operation. Furthermore, the uniform nip pressure tends to suppress wrinkles in the conveyed medium (material) and flapping due to speed fluctuations.

[0081] Fourth Embodiment In the fourth embodiment, a belt conveyor-type transport mechanism 4 will be described, which rotates a ring-shaped belt using transport rollers to transport media placed on the belt in the belt's rotation direction (transport direction). Fig. 11 is a perspective view of the belt conveyor-type transport mechanism 4 in the fourth embodiment. Fig. 12 is a schematic cross-sectional view of the transport mechanism 4 as viewed from one side in the axial direction.

[0082] The transport mechanism 4 includes the roller device 1 described in the first embodiment, a belt 310, a driven roller 320, and a support frame 350. The roller device 1 is the same as in the first embodiment, so a description thereof will be omitted. Note that it is also possible to configure a belt conveyor type transport mechanism 4 using the roller device 2 of the second embodiment instead of the roller device 1.

[0083] The belt 310 is a ring-shaped band member having a predetermined width in the axial direction, and is wound around the cylindrical portion 100 and driven roller 320 of the roller device 1. The belt 310 has a plurality of through-holes 311, 311... that penetrate the belt 310 in the thickness direction, dispersedly arranged on its surface (see FIG. 11 ). The driven roller 320 is a cylindrical member located downstream of the roller device 1 in the conveying direction and having a rotation axis CA3 parallel to the rotation axis CA of the roller device 1. When the cylindrical portion 100 of the roller device 1 rotates, the belt 310 wound around the cylindrical portion 100 rotates in the rotation direction of the cylindrical portion 100, and the driven roller 320 rotates in the same direction as the rotation of the belt 310. The support frame 350 is located between the roller device 1 and the driven roller 320 in the conveying direction and supports the driven roller 320. In this embodiment, the support frame 350 is provided with a suction mechanism (not shown) that draws air from the outside to the inside.

[0084] When a conveying operation is performed using the conveying mechanism 4, the cylindrical portion 100 of the roller device 1 is rotated counterclockwise with the conveyed medium (material) placed on the upper surface of the belt 310 (see FIG. 12 ). As a result, the belt 310 is rotated in accordance with the rotation of the cylindrical portion 100 and the driven roller 320, and the conveyed medium (material) placed on the upper surface of the belt 310 is conveyed in the conveying direction. During the conveying operation of the conveying mechanism 4, when the belt 310 passes above the support frame 350, a suction mechanism provided in the support frame 350 sucks air, and air is sucked through the through holes 311, causing negative pressure to act on the upper surface of the belt 310. This allows the conveyed medium (material) placed on the upper surface of the belt 310 to be stably held while being conveyed.

[0085] When such a belt conveyor-type transport mechanism 4 is configured using the roller device 1, the cylindrical portion 100 of the roller device 1 can rotate without distortion or tilt, thereby stably driving the belt 310. Furthermore, the highly stable cylindrical portion 100 of the roller device 1 makes it easier to adjust the belt tension to a constant level, thereby achieving a stable transport operation with little loss.

[0086] ===Other Embodiments= ...

[0087] In the above-described embodiments, in the roller device 1 and the roller device 2, the output shaft 32 of the reducer 30 or the output shaft 42 of the drive unit 40 is either an elongated rod-shaped shaft, and the cylindrical portion 100 is supported via the hub 50 attached to the rod-shaped output shaft 32 or the output shaft 42 using the shaft fastening portion 60. However, the output shaft 32 of the reducer 30 (the output shaft 42 of the drive unit 40) may be flange-shaped. In other words, the cylindrical portion 100 may be directly supported by the flange-shaped output shaft 32, 42 without using the hub 50.

[0088] FIG. 13 is a diagram illustrating an example in which the output shaft of the reducer 30 in the roller device 1 has been changed to a flange-type shaft. In FIG. 13 , a flange-type output shaft 33 is provided as the output shaft of the reducer 30. The flange-type output shaft 33 is a disk-shaped output shaft with a larger outer diameter than the rod-shaped output shaft 32 shown in FIGS. 2 and 3 , and one axial end (tip) is formed as a wide flat surface. A hub 50 is attached to this flat surface. The hub 50 can be attached to the flange-type output shaft 33 using mounting bolts 56, eliminating the need for a shaft fastener 60 for attachment. Using a reducer 30 (drive unit 40) with such a flange-type output shaft reduces the axial length compared to a rod-shaped output shaft 32, thereby enabling space savings and improving load-bearing capacity.

[0089] REFERENCE SIGNS LIST 1 Roller device (first embodiment), 2 Roller device (second embodiment), 3 Conveying mechanism (nip roll type conveying mechanism, third embodiment), 4 Conveying mechanism (belt conveyor type conveying mechanism, fourth embodiment), 10 Mounting support, 11 Upstream conveying support, 12 Downstream conveying support, 13 Lower support, 15 Fixing plate, 20 Support portion, 21 Fixing hole, 30 Reducer, 31 Housing, 32 Output shaft, 33 Flange type output shaft, 40 Drive portion, 41 Housing, 42 Output shaft, 45 Connection port, 50 Hub, 51 Insertion portion, 52 Flange portion, 521 Joint portion, 522 Ring portion, 54 Bolt hole, 55 Ventilation hole, 56 Mounting bolt, 60 Shaft fastening portion, 100 Cylindrical portion, 100a Cylindrical portion, 100b cylindrical portion, 101 pipe portion, 102 protrusion portion, 200 nip roll device, 210 mounting support, 220 pressure portion, 230 support portion, 240 nip roll, 310 belt, 311 through hole, 320 driven roller, 350 support frame, PL vertical wall portion (end plate), CA rotation axis (center axis), CA2 rotation axis (transport mechanism 3), CA3 rotation axis (transport mechanism 4)

Claims

1. A roller device provided in a conveying mechanism for conveying materials related to hygiene products in a conveying direction, the roller device having: a mounting post attached to a vertical wall portion; a support portion provided at the tip of the mounting post; a drive portion that rotates the roller device, the output shaft side of the drive portion being supported by the support portion; and a cylindrical portion that is rotatably attached to the output shaft and houses at least a part of the drive portion in a space on its inner circumference, the support portion being located at the center in the axial direction of the cylindrical portion.

2. A roller device according to claim 1, characterized in that the cylindrical portion is supported only by a hub attached to the output shaft.

3. A roller device as described in claim 2, wherein the cylindrical portion has a tube portion and a protrusion portion protruding from the inner peripheral side of the tube portion, the hub has a mating portion that mating with the protrusion portion and a ring portion having an outer diameter larger than that of the mating portion, and the outer diameter of the ring portion is smaller than the inner diameter of the tube portion.

4. A roller device according to claim 2, characterized in that the hub has an air hole for passing air from one side to the other side in the axial direction.

5. A roller device according to any one of claims 1 to 3, characterized in that the drive unit is supported by the support unit via a reducer.

6. A roller device according to claim 5, characterized in that the reducer is a planetary reducer, and the reduction ratio of the reducer is 1 / 3 to 1 / 5.

7. A roller device according to any one of claims 1 to 3, characterized in that the roller device has no portion that protrudes across the vertical wall portion from the side to which the mounting post is attached.

8. A roller device as claimed in any one of claims 1 to 3, characterized in that the mounting post is provided along the axial direction and is not disposed in at least one of the following locations: above the drive unit, below the drive unit, upstream of the drive unit in the conveying direction, and downstream of the drive unit in the conveying direction.

9. A roller device as described in claim 8, characterized in that the mounting posts are arranged in three locations among the above the drive unit, the below the drive unit, the upstream side of the drive unit in the conveying direction, and the downstream side of the drive unit in the conveying direction.

10. A roller device according to any one of claims 1 to 3, comprising a nip roll type transport mechanism that transports the material in the transport direction while sandwiching and pressurizing the material between a nip roll having a rotation axis parallel to the rotation axis of the roller device.

11. A roller device according to any one of claims 1 to 3, comprising a belt conveyor type transport mechanism that transports the material placed on a circular belt in the transport direction by rotating the belt.

12. A material transport method for transporting materials related to sanitary products in a transport direction using a transport mechanism equipped with a roller device, the roller device having a mounting post attached to a vertical wall portion, a support portion provided at the tip of the mounting post, a drive portion for rotating the roller device, the output shaft side of the drive portion being supported by the support portion, and a cylindrical portion rotatably attached to the output shaft and accommodating at least a portion of the drive portion in a space on the inner circumference side, the support portion being located at the center in the axial direction of the cylindrical portion.

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