Adjustable Drive Rollers for Conveyor Diversion
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Solution Overview
Problem
Existing conveyor systems with fixed-angle rollers are limited in diverting objects, leading to roller slip and object drift, requiring shutdown and belt replacement for direction or angle changes.
Innovation Solution
A conveyor system with angularly adjustable drive rollers that can be actuated to change the angle of engagement with conveyor belt rollers, allowing for diversion in various directions and angles while minimizing slip through gradual acceleration and braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed-angle conveyor belt rollers are used, then the conveyor system structure is simple, but the diverting direction and angle cannot be changed without shutting down and replacing the belt
Solution Approach 1:
The patent applies the dynamics principle by making the conveyor belt rollers rotatable about vertical axes in addition to their primary rotation about horizontal axes. This allows the rollers to be dynamically reoriented to different angles, enabling the conveyor system to divert objects at various directions and angles without requiring shutdown or belt replacement. The rollers can be rotated to different angular positions and maintained in those positions, providing adaptability while keeping the same physical belt in use.
2Speed
If friction plates are brought into contact with rollers to accelerate them, then the rollers can be driven, but roller slip occurs causing wear
Solution Approach 1:
The patent applies dynamics by enabling gradual acceleration of rollers through controlled angular rotation. Instead of suddenly engaging friction plates to accelerate rollers from zero to operating speed, the rollers can be gradually rotated into their operational angular position, allowing them to accelerate smoothly and progressively. This reduces slip and wear by avoiding sudden engagement and excessive friction forces.
Solution Approach 2:
The patent introduces an intermediary mechanism by using the roller's angular rotation capability as a mediator between the stationary friction plate and the roller's rotational motion. By controlling the angular position and rate of change of the rollers, the system mediates the acceleration process to minimize slip and wear while still achieving the necessary speed increase through friction engagement.
3Ease of operation
If friction plates or free-spinning rollers are disengaged from conveyor belt rollers, then the rollers are free to rotate, but objects drift across the belt
Solution Approach 1:
The patent applies dynamics by maintaining the ability to quickly re-engage and re-orient rollers to precise angular positions. When objects need to be held in position, rollers can be rotated to specific angles and maintained there, providing dynamic control over object lateral position. This allows the system to switch between free rotation mode (for ease of operation) and controlled position mode (for precision) as needed.
4Adaptability or versatility
If conveyor line is shut down to replace conveyor belt for changing diverting direction, then roller orientation can be changed, but productivity is reduced
Solution Approach 1:
The patent applies dynamics by enabling the rollers to be rotated to different angular positions while the conveyor belt remains in use and the system remains operational. This eliminates the need to shut down the conveyor line or replace the belt to change diverting directions. The rollers can be dynamically reoriented during operation, maintaining productivity while achieving the required adaptability for different diverting configurations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise control of object positioning and diversion at various angles with reduced roller slip and drift, allowing for flexible operation without shutting down the conveyor line.
Implementation Method 1
the rollers are driven by selectively bringing a friction plate located beneath the conveyor belt into and out of engagement with the rollers. When the plate engages the rollers, the rollers are caused to rotate in response to the frictional forces between the friction plate and the rollers.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
In one embodiment, a conveyor system (300) includes a conveyor belt (302) having a plurality of conveyor belt rollers (304) configured to divert objects (o) on the conveyor belt, and a drive mechanism that engages the conveyor belt rollers, the drive mechanism being configured to drive the conveyor belt rollers, the drive mechanism being adjustable such that the conveyor belt rollers can be selectively driven in a first angular direction and a second, opposite angular direction so that objects can be selectively diverted to either side of the conveyor belt at a desired diverting angle. One version of the drive mechanism has drive rollers (308) mounted in cartridges (320) and rack gears (342) engaging pinion gears (334) on the cartridges to adjust the orientation of the drive rollers relative to the belt rollers to drive them in selectively opposite angular directions.