Conveyor Roller Generator with Magnetic Slip Coupling
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Solution Overview
Problem
Conveyor belt assemblies face challenges in generating electricity along their entire length due to the impracticality of running electrical wires and existing generator configurations that are prone to failure from dust buildup and mechanical issues like seizure and friction-related problems.
Innovation Solution
A generator is directly connected to a conventional conveyor belt idler roller, with a rotor configured to rotationally slip when resistive torque exceeds a threshold, using a stator and rotor design with permanent magnets, a drive dog, and a resilient drive coupling to absorb torque variations and prevent wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a generator is integrated into a conveyor belt roller, then electricity can be generated along the conveyor belt assembly, but the generator is prone to seizure and friction-related failures due to dust buildup
Solution Approach 1:
A magnetic coupling mechanism is introduced as an intermediary between the conveyor roller and the generator rotor. The magnetic coupling transmits rotational force without direct mechanical contact, preventing dust from the conveyor environment from contaminating the generator internal components while maintaining reliable power transmission
Solution Approach 2:
The patent replaces direct mechanical connection with a magnetic field-based coupling system. The magnetic coupling creates a non-contact interface that eliminates mechanical friction and dust ingress pathways, substituting a vulnerable mechanical system with a more reliable electromagnetic transmission system
2Reliability
If a special roller with integrated generator is used, then electricity generation is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The system is divided into separate functional modules: the conventional conveyor roller remains independent, while the generator with magnetic coupling is implemented as a separate unit. This segmentation allows standard roller manufacturing to continue while adding electricity generation capability through a modular attachment, reducing overall manufacturing complexity
Solution Approach 2:
The magnetic coupling mechanism serves multiple functions: it transmits torque from the roller to the generator, allows relative motion accommodation, and provides dust sealing. This multi-functionality reduces the need for additional specialized components, simplifying the overall system design and manufacturing
3Power
If a drive shaft is used to transfer mechanical energy to the generator, then electricity generation is achieved, but dust buildup on the drive shaft causes operational failures
Solution Approach 1:
The patent eliminates the exposed drive shaft by replacing it with a magnetic coupling system. The magnetic field transmits rotational force without requiring a physical shaft that extends into the dusty conveyor environment, thereby preventing dust accumulation that would cause operational failures while maintaining full power transfer capability
4Ease of manufacture
If the generator rotor is directly connected to the conveyor roller, then simple installation is achieved, but the generator seizes when excessive torque is applied
Solution Approach 1:
The magnetic coupling creates a dynamic interface between the roller and generator rotor, allowing relative motion when excessive torque is applied. Instead of a rigid direct connection that leads to seizure, the magnetic coupling can slip or decouple under overload conditions, protecting the generator while maintaining simple installation
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 enables reliable electricity generation along conveyor belt assemblies by preventing generator seizure and reducing wear, while maintaining operational efficiency and safety by allowing rotational slipping when excessive torque is encountered.
Implementation Method 1
a rotor (14) configured to rotate about a central axis (22) of the stator (12)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A generator comprises a stator having a central axis and a rotor. The stator is configured and adapted to be supported by a portion of conveyor belt support structure. The stator comprises an opening aligned with the central axis configured and adapted to receive at least a portion of a shaft of a conveyor belt roller. The rotor is configured and adapted to connect to the conveyor belt roller in a manner such that the rotor and conveyor belt roller can collectively rotate about the central axis. The rotor encircles the stator and comprises a plurality of permanent magnets.