Composite Return Roller for Conveyor Belt Material Deposition
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Solution Overview
Problem
Mobile belt conveyors face issues with material deposition on return rollers, leading to irregular contact and safety concerns, particularly on short conveyors, where sticky products adhere permanently, causing operational irregularities and reducing the effectiveness of anti-trap protections.
Innovation Solution
The design incorporates return rollers with a central cylindrical body, an outer layer of high hardness (80 shore) for durability, and an intermediate layer of lower hardness (40 shore) for flexibility, forming a smooth surface that reduces material deposition and enhances longevity, along with a method of manufacturing using polyurethane-based materials and controlled polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a rubber sheet with low hardness is adhered to the return rollers to reduce material deposition, then the deposit of material is limited, but the flexibility of the rubber material limits the life of the lining during use and the rough surface becomes loaded with particles causing clogging
Solution Approach 1:
The return roller is constructed with a composite structure consisting of a polyurethane material that combines high hardness (70-90 Shore A) for durability and resistance to material deposition, while incorporating flexibility characteristics. This composite approach resolves the contradiction by providing both the hardness needed to resist clogging and the operational longevity required, unlike the soft rubber sheets that deform and wear quickly.
Solution Approach 2:
The invention changes the key parameter of hardness from low (rubber sheets at approximately 30-50 Shore A) to high (polyurethane at 70-90 Shore A) while maintaining operational effectiveness. This parameter change allows the roller surface to resist material adhesion and deformation, thereby extending service life and reducing clogging while still performing the function of supporting and guiding the conveyor belt.
2Device complexity
If the transport face is in direct contact with the return rollers on short conveyors, then the conveyor structure is simplified, but significant deposit of product accumulates on the return rollers causing irregular contact and safety issues
Solution Approach 1:
The polyurethane material used in the return roller provides a non-stick surface property that prevents product accumulation even when the transport face is in direct contact with the rollers. This material property allows the simplified conveyor structure to function effectively without the harmful effects of material deposition, resolving the contradiction between structural simplicity and material buildup.
Solution Approach 2:
Instead of using expensive and complex mechanisms to prevent material deposition (such as scraping systems or frequent maintenance routines), the invention employs a cost-effective polyurethane roller surface that inherently resists material adhesion. This provides a durable, low-maintenance solution that eliminates the need for complex anti-deposition mechanisms.
3Force
If a rough surface roller is used to support the return strand, then the roller provides good grip, but the roller becomes clogged with particles and requires frequent maintenance
Solution Approach 1:
The invention changes the surface characteristic from rough to smooth by using polyurethane material with high hardness (70-90 Shore A). This smooth surface prevents particle accumulation and clogging while maintaining adequate grip through the material's inherent friction properties and the roller's rotational motion, thereby reducing maintenance frequency without sacrificing essential grip function.
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 configuration reduces material deposition, improves roller longevity, maintains flexibility, and ensures smooth operation by preventing clogging, while being easy to produce and maintain, thus enhancing the conveyor's reliability and safety.
Implementation Method 1
a method of manufacturing a roller of a mobile belt conveyor comprising providing a mold and associating the mold with a rotation device; casting into the mold of a first material suitable for undergoing polymerization; rotating the mold by the rotation device so that the first material undergoes polymerization simultaneously
Data Source
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AI summary
The invention relates to a roller (24) for a moving belt conveyor adapted to support a conveyor belt. The roller (24) comprises an outer layer (50) intended to be in contact with the conveyor belt and having a first hardness. The roller (24) is characterized in that it further comprises an intermediate layer (52) extending under the outer layer (50), the intermediate layer (52) having a second hardness lower than the first hardness.