Modular Conveyor Chain Roller Unit Replacement
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Solution Overview
Problem
Conventional conveyor chains experience sliding wear between chain links and rollers, leading to backlash, uneven conveying, and increased operational complexity due to the need for frequent component replacement and directional changes, resulting in higher costs and complicated maintenance.
Innovation Solution
A conveyor chain design featuring chain links with integrally molded hinge portions and free rollers held in roller units, allowing for simple attachment and detachment of roller units from the longitudinal direction, eliminating the need for replacing entire chain links and facilitating easy rotation direction changes through engagement mechanisms and secure mounting systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the chain links are constituted of first and second members vertically united with rotating shafts held between them, then the conveyor chain can convey articles, but sliding wear occurs between chain links or rollers and the rotating shafts
Solution Approach 1:
The patent extracts the rotating shafts from the chain link structure and places them inside separate roller holders. The rollers with their shafts are mounted on the chain links via roller holders that attach to the chain link surfaces, separating the rotating component from the chain link body and eliminating direct contact between shafts and chain links, thus preventing sliding wear.
Solution Approach 2:
The roller holder acts as an intermediary component between the chain link and the roller assembly. It provides a mounting interface that connects the roller holder to the chain link surface without requiring the rotating shaft to contact the chain link, thereby mediating the connection and preventing wear.
2Ease of operation
If the rotating shafts are held between the first and second members, then the rollers can rotate to discharge articles, but wear progresses requiring replacement of chain links, rollers, or rotating shafts
Solution Approach 1:
The patent segments the conveyor chain into independent modular units: chain links, roller holders, and rollers. Each roller holder with its roller and shaft assembly can be independently attached to or removed from a chain link. This segmentation allows replacement of only the worn roller assembly without affecting the chain link or other components, greatly simplifying maintenance.
Solution Approach 2:
The patent enables selective replacement of worn roller assemblies while retaining the chain links and other functional components. The roller holders can be detached and replaced with new ones, while the chain links continue to be reused, effectively discarding only the worn components and recovering the durable chain link structure.
3Adaptability or versatility
If the first and second members are separated for replacement or rotation direction change, then components can be replaced, but the operation becomes complicated requiring disassembly and reassembly
Solution Approach 1:
The roller holder is designed as a separate modular unit that attaches to the chain link through a simplified interface. The attachment mechanism allows the roller holder to be easily detached and reattached without requiring separation of the chain link's first and second members, thus enabling rotation direction changes and replacements with minimal disassembly.
Solution Approach 2:
The roller holder incorporates a dynamic attachment mechanism that allows for quick connection and disconnection. The design enables the roller holder to be easily mounted or removed from the chain link by simple operations, facilitating rapid changes in rotation direction or replacement of rollers without complex disassembly procedures.
4Reliability
If the entire chain link is replaced when part is worn, then wear is addressed, but component costs increase
Solution Approach 1:
The patent divides the chain link system into replaceable roller holder modules and durable chain link bodies. Only the worn roller holders need to be replaced, while the expensive chain links are retained and reused. This segmentation strategy significantly reduces component replacement costs by replacing only the consumable parts.
Solution Approach 2:
The patent enables selective replacement of worn roller holders while recovering and reusing the chain links. Instead of discarding entire chain links when any component shows wear, the system allows recovery of the durable chain link structure and replacement of only the worn roller assemblies, reducing material waste and costs.
Data Source
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AI summary
Disclosed is a conveyor chain (100) in which a large number of chain links (110) on which components are loaded are linked at hinge sections by means of hinge pins (120) and in which a plurality of free rollers are provided protruding from both the front and rear surfaces of the chain links (110), wherein the plurality of free rollers are each rotationally held in roller holders to form roller units (130) and are formed so as to be attachable from the longitudinal direction in a unit attachment region of the chain links (110). By means of the aforementioned structure, it is possible to replace worn components by means of a simple operation and it is unnecessary to replace chain links (110) which have not become worn, costs are reduced, and it is simple to change the rotation direction of the free rollers.