Belt Unit Flange Design for Roller Stability
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Solution Overview
Problem
Conventional belt units in image forming apparatuses face issues with belt drifting due to flange removal caused by moment forces, increased size and cost from spring arrangements, and thin flange thickness leading to instability.
Innovation Solution
A belt unit design featuring a flange with a cylindrical portion inserted into the roller, where the inner edge of the flange's surface contacting the shaft is positioned closer to the center than the outer edge contacting the roller, balancing forces and reducing moment, thus preventing flange removal and maintaining stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flanges are arranged on both ends of the driven roller with outer diameters larger than the roller to prevent belt drifting, then belt drifting is prevented, but the flanges may be removed from the roller due to moment forces when the belt hits them
Solution Approach 1:
The flange transitions from a two-dimensional thin plate to a three-dimensional structure with a cylindrical portion extending in the radial direction. This dimensional change provides both belt-contacting surfaces for positioning stability and shaft-engaging surfaces for attachment stability, resolving the contradiction between preventing belt drifting and preventing flange removal.
Solution Approach 2:
The flange combines multiple functional surfaces in a single component: outer surfaces for belt engagement, inner cylindrical surfaces for roller engagement, and end surfaces for shaft engagement. This composite structure integrates the functions of belt positioning and flange attachment into one unified component, simultaneously achieving both reliability requirements.
2Ease of manufacture
If flanges are made thin and uniform in radial direction to reduce cost and weight, then manufacturing cost and weight are reduced, but the flanges may be removed from the roller when subjected to external force
Solution Approach 1:
The flange is segmented into distinct functional zones: a cylindrical portion for roller engagement and outer surfaces for belt engagement. This segmentation allows each zone to be optimized for its specific function while maintaining overall manufacturing simplicity through integration into a single molded component.
Solution Approach 2:
The flange exhibits local quality variations with different thicknesses in different regions. The cylindrical portion has sufficient thickness for reliable roller engagement, while other areas may be thinner for cost reduction. This localized thickness variation maintains reliability where needed while preserving manufacturing efficiency.
3Reliability
If springs are arranged on both ends of the shaft to apply spring pressure and prevent belt drifting, then belt drifting is prevented, but the size of the belt unit increases and necessary components increase
Solution Approach 1:
The spring component is extracted from the system and replaced by the geometric configuration of the flange itself. The flange's shape and positioning provide the belt-constraining function that previously required springs, eliminating unnecessary components while maintaining belt positioning stability.
Solution Approach 2:
The flange serves multiple functions simultaneously: it prevents belt drifting through its outer diameter, maintains attachment stability through its cylindrical portion, and eliminates the need for separate spring components. This multi-functionality reduces device complexity while preserving reliability.
Data Source
AI summary
At least one of a plurality of rollers supporting an endless belt includes a flange arranged on an end portion of the roller. The flange includes a cylindrical portion that is inserted into an opening portion of the roller at its end. Outer circumference of the cylindrical portion makes contact with inner circumference of the roller, and inner circumference of the flange makes contact with a rotation shaft of the roller. The inner edge of a surface where the flange is in contact with the rotation shaft is located on the inner side of the outer edge of a surface where the cylindrical portion is in contact with the roller in the longitudinal direction of the rotation shaft.