Conveyor Idler Mounting With Hinged Axle Holders
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Solution Overview
Problem
Existing conveyor systems face challenges in efficiently and quickly replacing idlers due to the need for partial disassembly and the use of various tools, which can be time-consuming and inconvenient, especially in heavier duty assemblies.
Innovation Solution
A framework that allows for tool-free removal and replacement of conveyor idlers, featuring hinged axle holders that can be swung into and out of engagement with the axle ends, enabling the outer idlers to be slid out and the central idler to be lifted out of keyed slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fasteners are used to construct the framework, then the framework and idler are securely assembled, but the replacement of idlers becomes time-consuming and requires substantial tools
Solution Approach 1:
The framework is divided into modular components with distinct mounting mechanisms. The uprights are segmented to accommodate different idler configurations, and the idlers themselves are designed as separate, interchangeable units. This segmentation allows for rapid disassembly and reassembly without requiring complete framework disassembly.
Solution Approach 2:
The mounting mechanism transitions from static fasteners to dynamic, movable components. The hinged mounting brackets can pivot between engaged and disengaged positions, allowing tool-free removal of idlers while maintaining secure attachment during operation. This dynamic capability resolves the contradiction between secure assembly and quick replacement.
2Strength
If traditional fasteners are used to construct the framework, then the framework and idler are securely assembled, but various tools are required for disassembly and reassembly
Solution Approach 1:
The mounting mechanism is designed to be self-servicing through the use of hinged brackets that can be manually pivoted without external tools. The spring-loaded retainers automatically engage and disengage, allowing operators to perform maintenance tasks without requiring specialized toolsets, thereby improving ease of operation while maintaining secure assembly.
Solution Approach 2:
The transition from static fasteners to dynamic hinged mechanisms enables tool-free operation. The hinged brackets move between locked and unlocked positions through simple manual manipulation, eliminating the need for wrenches, screwdrivers, or other tools while maintaining robust connection during conveyor operation.
3Strength
If heavier duty hardware is used for heavier duty assemblies, then the framework and idler are more securely assembled, but the replacement process becomes even more time-consuming and requires substantial tools
Solution Approach 1:
The mounting system is segmented into independent hinged brackets and spring retainers that can be operated separately. This modular approach allows heavy-duty connections to be broken down into simple, tool-free manipulation steps, reducing the perceived complexity of the replacement process while maintaining the strength required for heavy-duty applications.
Solution Approach 2:
The hinged mounting brackets provide dynamic connection capability that works across different duty levels. The same hinged mechanism that provides secure attachment for heavy-duty assemblies also enables easy tool-free removal, preventing the complexity from increasing with the duty level. The spring-loaded retainers automatically adapt to the load requirements while maintaining consistent ease of operation.
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
Enables rapid and tool-free replacement of idlers, reducing labor costs and minimizing conveyor downtime, while maintaining the structural integrity and load-handling capabilities of the conveyor system.
Implementation Method 1
The hinged, outboard axle holder can be swung into engagement with, and out of engagement with the axle ends
Implementation Method 2
hinged axle holders or mounts that can be selectively swung into engagement with, and out of engagement with the axle ends
Implementation Method 3
A spring-loaded pin or other fastener selectively retains the hinged, outboard axle holder in the engaged position
Data Source
AI summary
This invention provides a framework that allows for tool-free removal and subsequent replacement of conveyor idlers. The opposing framework uprights, which support outboard ends of each idler, respectively, include hinged axle holders/mounts that can be selectively swung into engagement with, and out of engagement with the axle ends. In this manner, the opposing outer idlers can be disengaged from each, respective, outboard axle holder and then slid out of corresponding inboard axle holders, which each define a socket for receiving the inboard axle end. Each hinged, outboard axle holder can be secured in an engaged orientation with the corresponding axle end using a pin, or other fastener that removably interengages with a lower, fixed portion of the outboard upright, where the two members overlap. The central idler is held in place in keyed slots in central uprights. The framework can define an equal troughing, unequal troughing or channel inset troughing framework arrangement.