Modular Conveyor Mat With Segmented Hinge Locking
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Solution Overview
Problem
Modular conveyor mats face challenges with weak locking provisions and high manufacturing costs due to the need for multiple module variants, which complicates assembly and affects the stability and force transmission of the mat.
Innovation Solution
A module design with a dividing plane allowing for division into two halves, featuring wider coupling elements for enhanced locking provisions and improved force transmission, while maintaining a reduced number of module types, includes adjustable locking mechanisms and guide elements for compatibility with conveyor tracks and drive gears, and liquid-transmissive surfaces for cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple module variants are used to form a brick pattern, then the mat can avoid continuous cracks and improve stability, but the manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The module is divided into two identical halves along a dividing plane, allowing a single module type to be segmented and arranged in staggered rows to form a brick pattern. This eliminates the need for multiple module variants while maintaining the stability benefits of the brick pattern configuration.
2Strength
If locking provisions are made stronger, then the hinge pin locking improves, but the manufacturing cost and device complexity increase
Solution Approach 1:
The locking provision is integrated directly into the hinge part structure as an axial protrusion that engages with a corresponding recess in the receiving space. This merging of the locking function into the existing coupling element geometry provides strong locking without adding separate locking components or increasing device complexity.
3Force
If coupling elements are made wider for better force transmission, then the force transmission improves, but the manufacturing cost increases
Solution Approach 1:
The module body is segmented along a dividing plane to create two identical halves. This segmentation allows the wider coupling elements to be manufactured as integral parts of the molded module half, distributing the material requirements and reducing per-unit manufacturing cost while maintaining the force transmission benefits of wider coupling elements.
4Ease of manufacture
If a single module type is used instead of multiple variants, then manufacturing cost decreases, but the ability to form a brick pattern and avoid cracks is compromised
Solution Approach 1:
The module is designed with a dividing plane that creates two asymmetric halves when divided, which can then be arranged in alternating staggered rows. This asymmetric segmentation of a single symmetric module type enables the formation of a brick pattern that avoids continuous cracks, maintaining mat stability while using only one module variant for manufacturing.
Data Source
AI summary
Module for a modular conveyor mat, comprising coupling elements at the front and rear of a body part. The coupling elements comprise a series of successive hinge parts and receiving spaces, wherein hinge parts and receiving spaces can interdigitate with receiving spaces and hinge parts of a similar module successive in convening direction, and successive modules are hingedly couplable using hinge pins extending transversely to the conveying direction, reaching through hinge bores provided in the hinge parts. The body part is provided in the middle with a dividing plane which extends parallel to the sides and along which the module is divisible into two module halves. The pairs of coupling elements located on the sides are, viewed in the direction of the main axis, implemented with a greater width than neighboring coupling elements of the body part. Further, pairs of coupling elements located on both sides of the dividing plane of the module are also implemented with the same width as the coupling elements with the greater width located on the sides.