Conveyor Crank-Piston Conversion for Low-Wear Reciprocating Motion
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Solution Overview
Problem
Conventional conveyor systems face challenges such as difficulty in controlling vibration, excessive friction leading to wear and tear, costly maintenance, and downtime due to complex mechanical devices that generate sudden forward and reverse drives, resulting in high repair costs and facility downtime.
Innovation Solution
A conveyor system with a foundation, tray assembly, motor assembly, and conversion assembly that converts rotary movement into reciprocating motion using a transition plate and connecting rod, featuring a piston and cylinder to smoothly advance materials while minimizing shock loads through elastic deformation of frame bumpers and flexible straps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional conveyor systems use complex mechanical devices with sudden forward and reverse drives, then material movement can be achieved, but wear and tear increases and repair costs rise
Solution Approach 1:
The patent employs a dynamic conversion assembly that transforms rotary motion into reciprocating linear motion through a connecting rod and piston mechanism. This dynamic conversion allows the system to achieve material movement without sudden reverse drives, reducing wear and tear on mechanical components while maintaining operational capability.
Solution Approach 2:
The patent replaces traditional complex mechanical drive mechanisms with a streamlined system using a motor assembly directly coupled to a conversion assembly. This substitution simplifies the mechanical system, eliminating the need for sudden forward and reverse drives, thereby reducing wear and tear and lowering repair costs.
2Ease of operation
If reciprocating and vibrating conveyors are used to move material, then material can be advanced along a path, but friction increases and service life decreases
Solution Approach 1:
The patent uses a dynamic conversion assembly that smoothly transforms rotary motion into reciprocating linear motion. This controlled dynamic conversion reduces sudden friction spikes and mechanical stress, thereby extending the service life of the conveyor system while maintaining material advancement capability.
Solution Approach 2:
The patent incorporates elastic elements that cushion the reciprocating motion, reducing impact forces and friction. This beforehand cushioning protects the system components from damage, extending service life while maintaining the ability to advance material along the path.
3Ease of operation
If pneumatic actuators are used to advance material, then material can be moved along a tray, but system complexity increases
Solution Approach 1:
The patent replaces pneumatic control mechanisms with a direct mechanical conversion assembly that uses a motor-driven crankshaft and connecting rod system. This substitution eliminates the complexity of pneumatic controls while maintaining the ability to advance material along the tray, using purely mechanical motion conversion instead.
4Ease of repair
If worn belts or components are replaced in traditional systems, then system functionality is restored, but downtime increases and costs rise
Solution Approach 1:
The patent employs a dynamic conversion assembly with smoothly operating mechanical components that reduce wear. This reduced wear minimizes the frequency of component replacements, thereby reducing downtime and repair costs while maintaining system functionality.
Solution Approach 2:
The patent designs a continuous reciprocating motion system that maintains constant material movement without interruption. This continuous operation reduces the frequency of maintenance stops, allowing for longer operational periods between repairs and minimizing overall downtime and associated costs.
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 system reduces wear and tear, minimizes maintenance costs, and maintains continuous operation by smoothly advancing materials with reduced friction and shock loads, enhancing the conveyor's service life and operational efficiency.
Implementation Method 1
The conversion assembly may be configured to convert rotary movement provided by the motor assembly into reciprocating movement of the tray assembly
Implementation Method 2
minimizing shock loads through elastic deformation of frame bumpers
Implementation Method 3
flexible straps... reduced friction and shock loads
Data Source
AI summary
A conveyor system may include a foundation, a tray assembly moveably connected to and suspended from the foundation, a motor assembly configured to move the tray assembly relative to the foundation, and a conversion assembly connected to the motor assembly and to the tray assembly. The conversion assembly may be configured to convert rotary movement provided by the motor assembly into reciprocating movement of the tray assembly. The conversion assembly may include a transition plate and a connecting rod. The transition plate may be connected to the motor assembly and rotatable about a rotation axis via the motor assembly. The connecting rod may include a piston and a cylinder. The cylinder may be pivotably connected to a crank journal of the transition plate. The piston may include a piston rod connected to the tray assembly and a piston head adjustably arranged in a chamber of the cylinder.