Conveyor Coupler Using Planetary Gears for Maintenance
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Solution Overview
Problem
Existing aggregate material conveyors face challenges with maintenance and part replacement due to the use of specially manufactured sprockets, which are inefficient and not widely used, leading to reduced longevity and productivity.
Innovation Solution
A conveyor coupler system utilizing standard planetary gear structures from Caterpillar machinery, connected by a coupler with a first portion and a second portion, including slots and ridge members, to securely attach and reduce the number of revolutions per minute, enhancing the connection between the first and second planetary gear structures, thus improving maintenance and part availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If specially manufactured sprockets are used to drive the chain link assembly, then the conveyor can transport aggregate material, but the maintenance requirements increase and part replacement becomes difficult
Solution Approach 1:
The patent applies universality by replacing specialized conveyor sprockets with standard planetary gear structures that are widely available in the industry. The coupler system with ridge members and slots provides a universal connection method that can be used with standard planetary gears from multiple manufacturers (e.g., Caterpillar), making parts easily replaceable and maintenance simpler while maintaining reliable conveyor operation
2Productivity
If specially manufactured sprockets are used, then the conveyor can function, but finding replacement parts becomes difficult and maintenance time increases
Solution Approach 1:
The coupler system enables quick replacement of planetary gear structures with standard industry parts, dramatically reducing maintenance downtime. The ridge member and slot design allows for tool-free or minimal-tool assembly and disassembly, enabling rapid part replacement that restores conveyor productivity quickly
Solution Approach 2:
The conveyor drive system is segmented into modular components (coupler, planetary gear structures, ridge members, slots) that can be independently replaced. This segmentation allows maintenance crews to replace only the worn planetary gears or coupler components without replacing the entire drive system, minimizing productivity loss
3Ease of repair
If standard planetary gear structures are used with a coupler system, then part availability improves and maintenance becomes easier, but the device complexity increases
Solution Approach 1:
The coupler system is segmented into simple, discrete components (coupler body, ridge members, slots, planetary gears) that are individually simple in design but collectively provide robust functionality. Each component can be manufactured using standard processes and is simple in itself, even though the assembled system provides enhanced maintenance capabilities
Data Source
AI summary
A conveyor coupler system for efficiently increasing the longevity and productivity of the conveyor. The conveyor coupler system generally includes a coupler including a first portion and a second portion, wherein the first portion extends from the second portion. The first portion includes a first connecting portion, wherein the first connecting portion extends within the first portion and includes at least one slot. The second portion includes a second connecting portion extending within the second portion and including a plurality of ridge members. The first connecting portion connects to a first planetary gear structure of a conveyor unit and the second connecting portion connects to a second planetary gear structure of the conveyor unit.