Modular Conveyor Mat Roller Density and Gap Reduction
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Solution Overview
Problem
Modular conveyor mats with rollers mounted on hinge pins face limitations in roller density and continuity due to space constraints, leading to gaps and instability in product support and orientation, especially when encountering wear strips and bend pulleys.
Innovation Solution
The design incorporates coupling parts with roller receiving spaces and a central rib, allowing for a high roller density by positioning rollers above the support surface and creating a recess for a driving gearwheel, enabling a continuous row of rollers and reducing the pitch between modules to 0.25-0.5 inches, facilitating close linkage and stable product conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If rollers are bearing-mounted on hinge pins to achieve high roller density, then roller density increases, but the height of conveyor mat modules increases leading to gap formation at bends
Solution Approach 1:
The patent positions rollers in the horizontal plane rather than vertically on top of modules, utilizing the interdigitating coupling part structure to accommodate rollers at module corners and edges. This dimensional repositioning maintains high roller density while keeping module height low, preventing gap formation at bends.
2Quantity of substance
If rollers are placed on coupling parts, then roller density increases, but the number of available coupling parts is limited leading to interruptions in roller rows
Solution Approach 1:
The patent segments the roller arrangement by placing rollers on both coupling parts and body parts of modules. This segmentation allows continuous roller rows to be formed across module boundaries, with rollers on coupling parts at corners and edges, and rollers on body parts filling intermediate spaces, eliminating interruptions in roller rows.
3Reliability
If module pitch is increased to at least 1 inch for proper driving, then driving reliability improves, but roller density decreases and product support stability deteriorates
Solution Approach 1:
The patent employs a flexible hinge connection between modules that allows dynamic adjustment of module spacing. The hinge pins enable modules to pivot and adapt to varying pitch requirements, maintaining driving reliability while allowing closer module spacing to achieve higher roller density and better product support stability.
4Ease of manufacture
If rollers project below the bottom of modules for simple driving from lower side, then driving simplicity increases, but product support stability decreases
Solution Approach 1:
The patent applies different roller positions to different locations: rollers on body parts project below the bottom for simple driving from the lower side, while rollers on coupling parts at corners and edges project above or at the module level to maintain product support stability. This local differentiation resolves the contradiction between driving simplicity and support stability.
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 achieves a roller density of 3500-6000 rollers/m2, ensuring stable product support and orientation, with the ability to pivot and maintain roller contact during curvature, preventing product loss and enhancing conveyor mat compactness.
Implementation Method 1
The rollers can then be relatively simply driven from the lower side of the conveyor mat modules, for instance by means of friction with a strip in the track guide that is stationary with respect to the modular conveyor mat
Implementation Method 2
successive conveyor mat modules are hingedly coupled with the aid of hinge pins extending transversely to the conveying direction and reaching through hinge holes in the coupling parts
Implementation Method 3
the body part at the bottom thereof is provided with a recess which, between mutually facing parts of the outer surfaces of successive rollers, leaves clear a space for therein receiving a tooth of a driving gearwheel
Data Source
AI summary
Modular conveyor mat (1), comprising a series of conveyor mat modules (2) successive in conveying direction, which conveyor mat modules are provided with a body part (5) extending transversely to a conveying direction, having a top (6) which bounds the body part at an upper side and a bottom (7) which bounds the body part at a lower side. The bottom is provided with a support surface (8) for supporting the body part on a plane guide (9). Successive conveyor mat modules are hingedly coupled with the aid of hinge pins (4) extending transversely to the conveying direction, reaching through hinge holes (16) in the coupling parts. At least a number of coupling parts are provided with a roller receiving space (13) having included therein a roller (19) which is bearing-mounted on the hinge pin, such that an outer surface of the roller is located wholly above the support surface and projects at least partly above the top of the body part. The body part is provided at the bottom thereof with a recess which, between mutually facing parts of the outer surfaces of successive rollers, leaves clear a space for therein receiving a tooth of a driving gearwheel.