Conveyor Intermediate Drive Reduces Wear
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Solution Overview
Problem
Modular link conveyors face high power requirements and excessive wear due to the need for gang-driven sprockets, which can lead to chain lag and stress, especially in longer conveyors or those with wide chains, and require a more adaptable and cost-effective drive arrangement.
Innovation Solution
An intermediate drive system with a first and second sprocket, supported by a gear train and retainer mechanism, positioned between guide rails to efficiently engage and drive the conveyor chain, reducing wear and stress by ensuring proper alignment and power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single gang-driven sprocket system is used at the conveyor ends, then the conveyor can be driven, but high power requirements and excessive wear occur on the chain and sprockets
Solution Approach 1:
The conveyor drive system is segmented into multiple independent drive units positioned at different locations along the conveyor. Each drive unit has its own sprocket and motor, dividing the total power requirement and mechanical stress across multiple points rather than concentrating it at single end sprockets. This segmentation reduces the power burden and wear on each individual drive component.
Solution Approach 2:
Intermediate drive units are introduced between the end sprockets and the chain. These intermediary drives are positioned at strategic locations along the conveyor to provide additional power application points and to support the chain, thereby reducing the mechanical stress and wear on both the chain and the end sprockets while lowering overall power consumption.
2Productivity
If the conveyor chain is made wider to handle more objects, then productivity increases, but chain lag in the middle worsens due to friction with guide rails
Solution Approach 1:
The drive system is divided into multiple segments along the conveyor length, with drive units positioned at intervals rather than concentrated at the ends. This segmentation ensures that each section of the wide chain receives adequate power and support, preventing chain lag in the middle sections while maintaining the productivity benefits of a wider chain.
Solution Approach 2:
Drive and support functions are distributed locally along the conveyor rather than being centralized. Each location along the conveyor has its own drive unit that provides localized power application and chain support, ensuring uniform chain movement across the entire width and length of the conveyor, thereby eliminating chain lag while maintaining high productivity.
3Productivity
If gang-driven sprockets are used to drive the conveyor, then the conveyor can operate, but excessive wear and stress occur on the sprocket and links
Solution Approach 1:
The single gang-driven sprocket system is replaced with multiple smaller drive units positioned along the conveyor. Each unit has its own sprocket that engages with a portion of the chain, distributing the mechanical stress and wear across multiple contact points. This segmentation significantly extends the service life of both the sprockets and chain links while maintaining continuous conveyor operation.
Solution Approach 2:
Intermediate drive units are introduced as mediators between the power source and the chain. These intermediary drives reduce the direct stress and wear on the chain links and end sprockets by providing additional support and power application points along the conveyor, thereby extending the durability of the chain and sprocket components.
4Reliability
If an intermediate drive system is added to reduce power consumption and wear, then reliability improves, but device complexity increases
Solution Approach 1:
The intermediate drive units are designed as universal, multi-functional components that combine the drive sprocket, retainer mechanism, and support functions in a single integrated unit. Each intermediate drive serves multiple purposes: driving the chain, retaining the chain on the sprocket, and supporting the chain to prevent lag. This multi-functionality reduces the need for separate components and simplifies the overall system despite adding drive capacity.
Solution Approach 2:
The drive and retention functions are merged into a single integrated intermediate drive unit. The retainer is combined with the sprocket assembly, eliminating the need for separate retention mechanisms. This merging of functions reduces the number of discrete components and simplifies installation and maintenance while achieving the reliability benefits of reduced wear and power consumption.
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
The intermediate drive system reduces power consumption and wear on the conveyor chain by ensuring efficient engagement and alignment, making it adaptable to various conveyor types and suitable for retrofitting without extensive effort.
Implementation Method 1
the sprocket and links of the conveyor chain... generate excessive wear and stress
Implementation Method 2
where the chain is particularly wide or the side links are guided along a guide rail and thus retarded by friction
Data Source
AI summary
An apparatus for conveying objects in a conveying direction includes a conveyor including a chain having at least a forward run supported by generally parallel and aligned supports spaced apart in a direction transverse to the conveying direction. A drive, which may be located between the spaced supports or between side links of the chain, includes a first sprocket for driving the chain in the conveying direction and at least one first retainer located between the supports for retaining the chain in engagement with the sprocket. Related methods are also disclosed.