Removable Conveyor Idler Frame for In-Service Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for inspecting, cleaning, and replacing conveyor belt idlers require shutting down the conveyor belt, posing safety risks and inefficiencies, while robotic solutions are expensive and prone to failure in harsh environments.
Innovation Solution
A conveyor idler replacement system using an H-frame with removable idler frames and a lift assembly that allows idlers to be safely removed and maintained outside the pull cord plane, enabling continuous conveyor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional methods for inspecting, cleaning, and replacing conveyor belt idlers are used, then maintenance can be performed on idlers, but the conveyor belt must be shut down causing operational interruptions and safety risks
Solution Approach 1:
The idler frame is extracted from the conveyor system by removing it from the H-frame structure. The grip arm with clamps grasps the idler frame and pulls it outward through the pull cord plane to a maintenance position where it can be inspected, cleaned, or replaced without affecting conveyor operation
Solution Approach 2:
The grip arm acts as an intermediary mechanism between the operator and the idler frame. It provides controlled manipulation of the idler frame, allowing it to be moved to and from maintenance positions while the conveyor operates, thereby enabling maintenance without direct human intervention in the hazard zone
2Ease of operation
If conventional maintenance methods are used, then idlers can be maintained, but workers must enter the pull cord plane creating safety hazards
Solution Approach 1:
The system enables self-service maintenance where the idler frame is autonomously manipulated by the grip arm mechanism. The clamps on the grip arm securely grasp the idler frame and move it to a maintenance position outside the pull cord plane, allowing workers to service idlers without entering the hazardous zone
Solution Approach 2:
The grip arm serves as an intermediary tool that extends the operator's capability to manipulate the idler frame from a safe position. It transfers the maintenance function from the hazardous zone to a safe zone, eliminating the need for workers to enter the pull cord plane
3Productivity
If robotic solutions are used for idler maintenance, then continuous conveyor operation can be maintained, but the system becomes expensive and prone to failure in harsh environments
Solution Approach 1:
The maintenance system is segmented into simple, discrete components: the H-frame structure, the grip arm, and the clamps. Each component performs a specific function and can be independently maintained or replaced. This modular approach reduces complexity compared to integrated robotic systems while enabling continuous conveyor operation
Solution Approach 2:
The grip arm and clamp assembly represents a simple, replaceable mechanism that can be manufactured at low cost. If these components wear or fail in harsh environments, they can be easily replaced without investing in expensive robotic systems, making the solution more economical and reliable for harsh conditions
Data Source
AI summary
A conveyor idler replacement system in one example with an H-frame (support frame). The system including a base with a first vertical strut extending from the base, a second vertical strut extending substantially vertically from the base; each of the first vertical strut and second vertical strut comprising a first idler frame bracket on a first longitudinal side of the H-frame; a first idler frame extending between the first idler frame bracket on the first vertical strut and the first idler frame bracket on the second vertical strut; at least one idler attached to the first idler frame, the idler configured to rotate, configured to support a conveyor belt. Including a system for lifting the belt and replacing idler frames.