Conveyor Roller Bearing Element With Shoulders

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Solution Overview

Problem

Existing roller conveyors face challenges with complex and energy-intensive drive systems, leading to high friction losses, wear, and assembly complexities, especially in curved conveyors where deflection of transmission elements increases friction and wear.

Innovation Solution

A roller conveyor system featuring a conveyor frame with elongated bearing elements allowing floating bearings and support rollers arranged to minimize friction, using a polyurethane round belt that rests tangentially on the rollers, and a drive system with a deflection roller setup that reduces the number of deflections and supports the belt on multiple rollers to maintain tension without additional tensioning devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a large number of driven rollers with their own drive units are used, then each roller can be driven independently, but the system becomes complex and expensive

Engineering Contradiction:

Improvedriven roller independenceVSAvoiddrive system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple driven rollers are merged into a single drive unit through a common drive shaft that extends through all rollers. The drive shaft rotates all rollers simultaneously, eliminating the need for individual drive units at each roller location. This reduces system complexity while maintaining the ability to drive multiple rollers independently through the shared mechanical connection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The common drive shaft serves multiple functions: it drives all rollers along the conveyor path, provides structural support for the roller assembly, and enables synchronized rotation of multiple rollers. This multi-functional design reduces the number of separate components needed, simplifying the overall system while achieving reliable driven roller operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Power

If transmission elements wrap around many rollers, then power can be transmitted to multiple rollers, but friction losses and energy consumption increase

Engineering Contradiction:

Improvepower transmission capabilityVSAvoidfriction loss

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The transmission element is extracted from the traditional belt-and-pulley configuration and replaced with a direct mechanical connection through drive shafts and gears. Each driven roller is connected to the drive shaft via a gear engagement that occurs at a single point rather than requiring continuous wrapping. This eliminates the friction losses associated with belt wrapping while maintaining effective power transmission to multiple rollers.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The friction-based belt transmission system is replaced with a gear-driven mechanical system. Gears engage with the drive shaft to transmit power directly to each roller without requiring continuous contact or wrapping. This substitution reduces energy loss through friction while maintaining the ability to distribute power across multiple rollers efficiently.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Length of moving object

If belts are shortened and welded on site, then the required length can be achieved, but welding quality is difficult to ensure

Engineering Contradiction:

Improvebelt lengthVSAvoidwelding quality

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The transmission system is segmented into modular components with standardized lengths. Drive shafts and gears are designed as discrete, replaceable units that can be assembled in a predetermined sequence. This segmentation eliminates the need for on-site welding or custom-length fabrication, as each component is manufactured to precise specifications and assembled using standardized connection methods that ensure consistent quality.

Inventive Principle:

Principle #1Segmentation

4Power

If the belt is strongly tensioned to achieve targeted effect, then power transmission is improved, but wear and energy loss increase

Engineering Contradiction:

Improvepower transmission efficiencyVSAvoidwear and energy loss

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The friction-based belt tensioning system is replaced with a gear-driven positive engagement system. Gears mesh with the drive shaft to transmit power through direct mechanical engagement rather than relying on friction from belt tension. This eliminates the need for high tension forces, reducing wear on components and minimizing energy loss while maintaining effective power transmission to all driven rollers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP2619116B1Roller conveyor comprising a bearing element with shoulders

Publication Date: 2017.04.12 INTERROLL HLDG

AI summary

The invention relates to a conveyor-section bearing element (50) for fitting to a conveyor frame (10) of a roller conveyor (1). Said conveyor-section bearing element (50) has at least one bearing bed (54) for supporting a conveyor roller (20) on the conveyor frame (10) and also has at least one roller shoulder for supporting an idler or supporting roller (33). The invention also relates to a retrofit kit and to a roller conveyor (1) comprising a conveyor section bearing element (50) of this type.