Bearingless Roller Assembly for Singulator Noise Reduction
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Solution Overview
Problem
Conventional roller assemblies in singulators of conveyor systems generate excessive noise and pose safety hazards due to bearing degradation from dirt and contaminants, leading to increased maintenance costs and potential OSHA regulation violations.
Innovation Solution
A roller assembly design featuring a central rod with rotatably mounted rollers made of ultra-high molecular weight plastic or high-density polyethylene, eliminating the need for bearings by using offset shafts and collars to maintain roller alignment and rotation, reducing friction and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional bearings are used in roller assemblies, then the rollers can rotate smoothly, but the bearings degrade from dirt and contaminants causing increased noise and safety hazards
Solution Approach 1:
The patent removes the bearings entirely from the roller assembly design. Instead of using conventional bearings that require lubrication and are susceptible to contamination, the invention uses a bearingless configuration where rollers rotate on a central shaft through direct contact with a low-friction surface, eliminating the source of noise and safety hazards associated with bearing degradation
Solution Approach 2:
The patent replaces the mechanical bearing system with an alternative rotational mechanism. The rollers are mounted to rotate about a central shaft where the roller surface directly contacts the shaft surface, creating a simplified mechanical system that eliminates complex bearing components and their associated maintenance issues
2Object-generated harmful factors
If bearings are used in roller assemblies, then initial noise levels may comply with OSHA guidelines, but noise levels increase over time as bearings wear down
Solution Approach 1:
By extracting the bearings from the system entirely, the patent eliminates the component that causes noise levels to increase over time. The bearingless design ensures consistent, low noise operation throughout the operational life of the rollers without the degradation issues that plague conventional bearing systems
Solution Approach 2:
The patent employs rollers made from ultra-high molecular weight plastic or high-density polyethylene that are designed to be simple, inexpensive components. While the individual rollers have limited lifespans, their low cost and simplicity mean they can be easily replaced without the noise and complexity issues of conventional bearing systems, maintaining reliable low-noise operation
3Ease of operation
If bearings are used in roller assemblies, then the rollers can function properly, but the system requires guarding to prevent safety hazards from rotating bearings
Solution Approach 1:
The patent removes the hazardous bearing components from the roller assembly. By eliminating the exposed rotating bearings that require guarding, the invention maintains proper roller function while removing the safety hazard, allowing the conveyor system to operate without additional safety guards
Solution Approach 2:
The patent substitutes the conventional bearing mechanism with a bearingless rotational system where rollers mount directly to the central shaft. This mechanical substitution eliminates the exposed bearing surfaces that create safety hazards, allowing workers' clothing to not get wrapped around exposed bearings while maintaining smooth roller rotation
4Productivity
If conventional roller assemblies are used, then the conveyor system can operate, but bearing failure requires shutdown and replacement, increasing downtime and maintenance costs
Solution Approach 1:
By taking out the bearings that are prone to failure and contamination, the patent eliminates the component that causes unplanned shutdowns. The bearingless roller assemblies operate reliably without the maintenance issues of conventional bearings, reducing downtime and allowing continuous conveyor operation
Solution Approach 2:
The patent uses simple, inexpensive roller assemblies made from durable plastics that can be easily replaced if needed. While the rollers themselves may have limited lifespans, their low cost and simplicity mean they can be quickly swapped without the complex bearing replacement procedures, minimizing downtime and maintenance costs
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
The solution significantly reduces noise levels, extends roller lifespan, and minimizes maintenance needs, ensuring compliance with OSHA regulations and reducing the cost of replacement parts.
Implementation Method 1
each roller is made of ultra-high molecular weight plastic, wherein each roller has a center passageway that directly contacts an outer surface of the central rod... each roller is made of a high density polyethylene, wherein each roller has a center passageway that directly contacts an outer surface of the central rod
Data Source
AI summary
A roller assembly for use in a conveyor system is disclosed. The roller assembly includes a central rod having first and second ends and a longitudinal axis. The roller assembly includes a plurality of rollers rotatably mounted to the central rod such that adjacent rollers abut each other. A first shaft extends through each of the plurality of rollers and is offset from and extends parallel to the longitudinal axis of the rod, causing the plurality of rollers to rotate about the central rod in unison. A first collar and a second collar are mounted on respective first and second ends of the central rod. Each collar is selectably movable to the central rod so as to hold the plurality of rollers in a fixed position along a length of the central rod. A conveyor system with the roller assembly is also disclosed.