Ceramic Conveyor Roll Torque Transmission via Internal Resilient Connection
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Solution Overview
Problem
Conventional conveyor roll assemblies for high-temperature applications face challenges such as difficult assembly, eccentric rotation, thermal expansion issues, energy loss due to thermal bridges, and high manufacturing costs, particularly when using ceramic rolls with metal end caps or external torque transmission systems.
Innovation Solution
A torque transmission and support means is integrated inside the ceramic spool, utilizing a resiliently deformable connecting portion with elongated holes and thicker portions to provide a frictional connection, eliminating the need for external end caps and allowing direct connection to a drive mechanism, while being thermally isolated and self-centering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If metal end caps are used to fasten to the ceramic spool, then the mounting to drive mechanism becomes easy, but thermal expansion differences cause eccentric rotation and slippage at high temperatures
Solution Approach 1:
The invention extracts the problematic metal end caps from the system and replaces them with a drive shaft made of ceramic material that matches the spool's thermal expansion characteristics. This eliminates the thermal expansion mismatch while maintaining the drive function.
Solution Approach 2:
The invention changes the material parameter of the drive shaft from metal to ceramic, which fundamentally alters the thermal expansion behavior to match the spool. This parameter change ensures reliable connection at high temperatures while maintaining ease of mounting.
2Ease of manufacture
If O-rings are used to fasten end caps to the spool, then assembly is simple, but the O-rings lose holding power at elevated temperatures causing slippage and eccentric rotation
Solution Approach 1:
The invention removes the O-ring fastening system entirely and replaces it with a direct interference fit between the ceramic drive shaft and spool. This eliminates the temperature-sensitive O-ring while maintaining assembly simplicity through the tapered insertion design.
Solution Approach 2:
The invention uses monolithic ceramic material for both the spool and drive shaft, creating a thermally compatible composite system that maintains fastening reliability at high temperatures unlike the metal-O-ring combination.
3Power
If external end caps are used for torque transmission, then connection to drive means is possible, but energy is lost through thermal bridges and manufacturing costs increase
Solution Approach 1:
The invention applies local quality by making the drive shaft and spool identical in material (ceramic) specifically at the connection interface, eliminating thermal bridges. This localized material matching prevents energy loss while maintaining torque transmission capability.
Solution Approach 2:
The invention uses ceramic-ceramic composite construction for the drive shaft and spool, creating a thermally isolated system that eliminates thermal energy loss through the drive connection while maintaining structural integrity for torque transmission.
4Reliability
If ceramic rolls are used in high temperature environment, then superior performance is achieved, but the material is difficult to work with and frangible
Solution Approach 1:
The invention segments the conveyor roll system into a ceramic spool and a separate ceramic drive shaft that can be assembled. This allows the ceramic components to be manufactured separately using optimal processes for each, then joined together, reducing overall manufacturing difficulty while maintaining high temperature performance.
Solution Approach 2:
The invention introduces a tapered interference fit interface as an intermediary connection method between ceramic components. This intermediate design feature facilitates assembly of fragile ceramic parts without requiring complex joining processes, reducing manufacturing difficulty while preserving ceramic integrity.
5Force
If metal spindles are used to rotate the ceramic roll through compression stress, then rotating driving force is improved, but assembly becomes difficult
Solution Approach 1:
The invention removes the metal spindle system with its complex friction material interfaces and replaces it with a simplified ceramic drive shaft using interference fit. This extraction eliminates assembly difficulty while maintaining sufficient driving force through the direct ceramic-ceramic connection.
Solution Approach 2:
The invention substitutes the mechanical friction-based connection system with a thermal-expansion-matched interference fit system. This mechanical substitution simplifies assembly by eliminating the need for friction material application and complex alignment procedures.
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
This solution enables reliable torque transmission and support within a wide temperature range, reduces manufacturing costs, minimizes energy loss, and allows for easy installation and reusability, with the ability to maintain torque transmission even at elevated temperatures without external support, thus overcoming the limitations of prior technologies.
Implementation Method 1
The connecting portion is mechanically and resiliently deformed so that the torque transmission and support means is frictionally connected to the spool
Implementation Method 2
The connecting portion is mechanically and resiliently deformed
Implementation Method 3
The torque transmission and support means is arranged inside a bore of a ceramic spool
Data Source
Figure 1
Figure 2~3
AI summary
A conveyor roll assembly (1) for use at high temperature comprising a) a ceramic spool (2) having a flexural strength of at least 15 MPa and an external diameter D and, b) a torque transmission and support means (3) of a general cylindrical shape and having a longitudinal axis, comprising a body and b1. a supporting portion comprising at least one cylindrical supporting surface (10) and, b2.a connecting portion that is mechanically and resiliently deformed, comprising at least two distinct connecting surfaces, frictionally connecting the torque transmission and support means (3) to the ceramic spool (2), characterized in that at least one end of the ceramic spool has an axial, centered bore of a diameter 10mm ≤ d ≤ 3/4 D, preferably ≤ 1/3D and a depth Dd ≥1.5 d and in that the torque transmission and support means (3) is provided in the at least said bore of the ceramic spool (2).