Composite Roller Flange Structure for Stable Conveyor Roller Fit
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Solution Overview
Problem
Conventional conveyor rollers face challenges in achieving a permanent, tight fit between roller bases and shells, particularly under high loads and temperature fluctuations, leading to loosening and relative rotation due to material expansion differences, and increased inertia with metallic bases.
Innovation Solution
A roller flange comprising a plastic body with a metallic ring and bearing, embedded in the plastic, features locking means and pins for transmitting axial and radial forces, ensuring secure attachment and torque transmission, even under varying loads and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If roller bases and roller shell are made of different materials (metal and plastic), then the connection loosens due to different thermal expansion, but using same material increases mass and inertia
Solution Approach 1:
The roller flange combines plastic and metal materials in a composite structure where the plastic body provides lightweight properties and the embedded metal ring provides dimensional stability and force transmission capability, resolving the contradiction between weight and connection stability
Solution Approach 2:
The metal ring is embedded only in specific regions of the plastic body where force transmission is needed, providing local reinforcement for axial and radial forces while maintaining overall lightweight construction
2Reliability
If conventional roller bases are used, then axial displacement and relative rotation occur under load, but adding locking mechanisms increases device complexity
Solution Approach 1:
The locking means and force transmission elements are integrated into the roller flange structure itself, combining multiple functions (locking, force transmission, torque transmission) into a single unified component rather than separate assembly elements
Solution Approach 2:
The composite plastic-metal structure inherently provides both locking capability and force transmission, eliminating the need for additional complex mechanical locking mechanisms
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 provides a durable and lightweight connection that prevents axial displacement and relative rotation, maintaining dimensional stability and reducing inertia, while allowing for efficient torque transmission.
Implementation Method 1
The ring has elements for force transmission positioned on or distributed over a surface, for example the circumferential surface, of the plastic body. The elements for force transmission comprise one or more locking means for transmitting an axial force between the roller and the roller flange
Implementation Method 2
If, in conventional implementations, the roller shell and the roller bases are made of different materials, for example the roller shell is made of metal and the roller bases are made of plastic, the connection between the two soon loosens due to different thermal expansion of the different materials
Data Source
AI summary
A roller flange for mounting on an end face of a cylindrical or drum-shaped roller comprises a substantially annular plastic body, a bearing and a metallic ring surrounding the bearing. The ring and the bearing are at least partially embedded in the plastic body. The ring has elements for force transmission, which are positioned distributed at or on a surface of the plastic body. The elements for force transmission comprise at least one locking means for transmitting an axial force between the roller and the roller flange, and at least one pin for transmitting a radial force between the roller and the roller flange.