Conveyor Roller Coupling Bushing for Low-Noise Torque Transfer
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Solution Overview
Problem
Existing motor-driven conveyor rollers face issues with high noise levels, deformation due to excessive pressure, and maintenance challenges, particularly with fluctuating tolerances and lubrication, which complicates torque transmission and increases production costs.
Innovation Solution
A motor-driven conveyor roller utilizing a selective punctual frictional or cohesive connection, featuring radial lugs with flexible noses and spot welding for torque transmission, allowing for higher tolerances and easier maintenance, while avoiding deformation and oil interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circumferential frictional connection is used for torque transmission, then reliable torque transmission is achieved, but the roller body deforms due to excessive pressure and high noise levels occur
Solution Approach 1:
The coupling bushing is divided into multiple radial lugs (at least three) that are distributed around the circumference. Instead of a continuous circumferential frictional connection, torque is transmitted through discrete point contacts at the lug tips, segmenting the contact area and reducing pressure concentration that causes deformation and noise.
Solution Approach 2:
The radial lugs are designed with flexible noses that have different structural properties than the rigid lug bodies. The flexible noses locally adapt to the roller body surface, ensuring reliable torque transmission at contact points while distributing pressure to avoid deformation of the roller body.
2Reliability
If tight manufacturing tolerances are enforced to ensure proper frictional engagement, then reliable torque transmission is achieved, but production costs increase
Solution Approach 1:
The radial lugs are designed with flexible noses that can elastically deform to accommodate variations in manufacturing tolerances. This flexibility allows the coupling bushing to maintain reliable torque transmission even when there are deviations in the dimensions of the roller body or coupling bushing, eliminating the need for tight tolerances and reducing production costs.
3Ease of operation
If the roller body is lubricated to reduce friction during operation, then operational smoothness is improved, but the frictional engagement for torque transmission is impaired
Solution Approach 1:
The flexible noses act as an intermediary element between the rigid lug structure and the roller body surface. They provide a controlled frictional engagement that maintains torque transmission effectiveness while allowing the roller body to remain lubricated for smooth operation. The flexible material of the noses can conform to the lubricated surface without being excessively impaired by the oil film.
4Reliability
If a complex clamping mechanism with multiple components is used for torque transmission, then reliable engagement is achieved, but device complexity and maintenance requirements increase
Solution Approach 1:
The coupling bushing integrates multiple functions into a single component: torque transmission through radial lugs, accommodation of manufacturing tolerances through flexible noses, and structural support as part of the drive unit assembly. This merging of functions eliminates the need for separate clamping mechanisms, adjustment devices, and maintenance components, simplifying the overall device while maintaining reliable engagement.
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 solution provides a cost-effective, low-noise, and maintenance-friendly torque transmission method that compensates for manufacturing tolerances and maintains effective frictional connections even with oil-lubricated rollers, preventing deformation and reducing production complexity.
Implementation Method 1
The radial lugs ( 54 ) are in contact with the inner circumferential surface ( 12 ) in order to form a punctiform frictional connection between the coupling bushing ( 50 ) and the roller body ( 2 ).
Implementation Method 2
A motor-driven conveyor roller utilizing a selective punctual frictional or cohesive connection, featuring radial lugs with flexible noses and spot welding for torque transmission
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Motor-driven conveying roller (1) for conveying installations for the purpose of conveying containers, pallets and the like, having a roller body (2), of which the outer circumferential surface constitutes a bearing surface for articles, having a drive unit (18), which is arranged within an interior (14) of the roller body (2), and having a coupling unit (30), which is designed for transmitting a torque from the drive unit (18) to an inner circumferential surface (12) of the interior (14) of the roller body (2) and has a coupling bushing (50), which has a drive portion, which is connected to the drive unit (18), and an outer, peripheral output portion (52), wherein the coupling bushing (50) is connected to the inner circumferential surface (12) of the roller body (2) in a frictionally fitting and/or integral manner, for torque-transmitting purposes, only at certain points.