Surface-Mounted Conveyor Drive with Floating Chassis Tensioning

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Solution Overview

Problem

Current conveyor systems require a sub-surface drive mechanism, which is costly and laborious to install, and can be hindered by facility design constraints such as pipes and wiring, leading to increased costs and delays in manufacturing line setup.

Innovation Solution

A surface-mounted drive mechanism with a floating chassis and automatic tensioning system that uses a calibrated tow chain, allowing for adjustable speed and preventing chain tangling, and includes features like tow pin assemblies and anti-backup components for stable operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sub-surface drive mechanism is used, then the conveyor system can operate with proper chain tension, but the installation becomes costly and laborious requiring floor cavity creation

Engineering Contradiction:

Improvechain tension stabilityVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The drive mechanism is inverted from the conventional sub-surface location to a surface-mounted position. The take-up system is mounted on top of the floor rather than below it, eliminating the need to create floor cavities while still providing the necessary chain tensioning function.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The take-up system utilizes the vertical dimension by mounting above the floor surface and using gravity-acting components that hang downward. This dimensional shift allows the system to achieve proper chain tension without modifying the floor structure, as the tensioning mass operates from above rather than requiring subsurface installation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If a sub-surface drive mechanism is used, then chain tension can be maintained, but facility design constraints such as pipes and wiring hinder installation and increase costs

Engineering Contradiction:

Improvechain tensionVSAvoidfacility layout flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

By inverting the drive mechanism location from below the floor to above it, the system avoids all subsurface obstructions such as pipes, wiring, and structural elements. The take-up system can be positioned anywhere on the floor surface without being constrained by underground facility infrastructure.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The drive mechanism is extracted from the floor structure entirely, removing it from the constrained subsurface environment. This allows the system to be installed independently of facility design constraints, as it operates from the floor surface rather than requiring integration with subsurface infrastructure.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If a sub-surface drive mechanism is used, then the conveyor can operate, but installation time and costs increase due to floor cavity creation

Engineering Contradiction:

Improveconveyor operationVSAvoidinstallation time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The drive mechanism is inverted to a surface-mounted configuration, eliminating the time-consuming process of creating and preparing floor cavities. Installation becomes a simple matter of mounting components on the floor surface, dramatically reducing installation time while maintaining full operational capability.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The surface-mounted take-up system uses simpler, less permanent installation methods compared to subsurface embedding. The system can be installed and removed without permanent floor modifications, reducing both installation time and associated labor costs while maintaining operational effectiveness.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

This solution reduces installation costs and time by eliminating the need for a sub-surface cavity, enhances operational stability, and allows for flexible conveyor system design adaptable to various manufacturing processes.

Implementation Method 1

a spring for applying a tensioning force to the drive mechanism

Methodology Applied

Scientific EffectSpring: Spring

Implementation Method 2

a floating-chassis take-up system... allowing for adjustable speed and preventing chain tangling

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS9969561B2Systems, methods, and apparatus for improved conveyor system drive

Publication Date: 2018.05.15 RHODES PATENT HLDG LLC

AI summary

The invention relates generally to conveying systems, for moving work pieces from work station to work station including conveyors which generally move at a constant speed and include load carrying units which can be coupled for movement therewith between work stations and uncoupled from the conveyor so that they will be stationary at the work stations while work is done on a work piece carried by the load carrying units. More particularly, the present invention pertains to improved systems, methods, and apparatuses for providing locomotion and control to a conveyor system including surface-mounted drive system and adjustable, automatic take-up system with floating drive chassis. The present invention also pertains to elevated conveyor systems comprising many of the same components as the surface-mounted conveyor systems.