Belt Conveyor Guide Roller Axial Segments
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Solution Overview
Problem
Conventional belt conveyor assemblies face issues with conveyor belts moving transversely to the conveying direction, leading to damage and production stagnation, due to the limitations of self-tracking methods like crowned pulleys and spring-loaded elements which result in high lateral forces, friction, and premature wear.
Innovation Solution
A belt conveyor assembly with a guide roller surface composed of axially movable segments and ball bushings, where the segments are connected to shafts and reset elements, allowing for smooth resetting and maintaining belt alignment without excessive lateral forces, using a combination of ball bushings and reset elements to ensure the segments return to their original position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring-loaded elements are used to reset segments, then segments can return to middle position, but large lateral forces are generated that are detrimental to belt life
Solution Approach 1:
A guide block with an inclined surface is introduced as an intermediary between the segment and the reset element. The inclined surface allows the reset element to push the segment axially during rotation, converting the resetting action into a gradual, low-force process rather than a sudden spring-loaded correction, thereby minimizing lateral forces on the belt.
Solution Approach 2:
The segment resetting mechanism is made dynamic through the rotation of the guide roller. As the guide roller rotates, segments that have displaced axially are gradually pushed back to their middle position by the inclined surface of the guide block, allowing resetting to occur continuously during rotation rather than requiring high static spring forces.
2Strength
If segments are made stiffer with ribs, then resistance to deflection increases, but the segment requires more force to reset to original position
Solution Approach 1:
The resetting process is made dynamic by utilizing the rotation of the guide roller. The inclined surface of the guide block pushes the stiff segment gradually back to its middle position during rotation, converting a potentially high instantaneous resetting force into a distributed force over time, making it feasible to reset even stiff segments with ribs.
3Reliability
If guide roller and support are arranged exactly parallel, then transverse belt movement is prevented, but manufacturing and alignment precision requirements increase
Solution Approach 1:
The guide roller surface is segmented into multiple axially movable segments. This segmentation allows each segment to independently adjust axially, compensating for minor misalignments between the guide roller and support. The segments can move to accommodate variations in positioning, maintaining proper belt tracking without requiring extremely high manufacturing and alignment precision.
Solution Approach 2:
The axial position of segments is made variable rather than fixed. By allowing segments to move axially, the system can adapt to variations in roller alignment and maintain proper belt tracking. This parameter change from fixed to movable axial position enables the system to tolerate greater manufacturing tolerances while still preventing transverse belt movement.
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 configuration effectively prevents transverse movement of the conveyor belt, reducing wear and extending the lifespan of the belt and components, while minimizing the need for frequent replacements and maintaining production efficiency.
Implementation Method 1
The guide roller comprises ball bushings for engaging the shafts
Data Source
Figure 1
Figure 2~3a
Figure 3b~3c
AI summary
The invention provides a belt conveyor assembly comprising a guide roller, with a guide roller axle (7), wherein the roller surface is configured from a number of axially movable segments (la, lb,...) distributed over the circumference of the roller surface and secured from rotating around the roller axle, characterized in that the belt conveyor assembly comprises a reset element (2a, 2b), and the guide roller (100) comprises a number of shafts (5), wherein each segment of the guide roller is connected to one or more shafts (5), and wherein the guide roller (100) comprises ball bushings (6) for engaging the shafts (5).