Conveyor Roller Nonlinear Bore for Axial Migration Prevention

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Solution Overview

Problem

Conveyor belt returnway rollers tend to migrate axially along the shaft due to forces from the belt, causing belt misalignment and noise, and existing solutions like shaft clamps and duct tape are either expensive or ineffective.

Innovation Solution

A support roller with a nonlinear bore hole is designed to constrain the roller to a specific operational portion of the shaft, using offset slots or a v-shaped track to prevent axial movement while allowing free rotation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a cylindrical bore hole is used for mounting the roller on a round shaft, then the roller can be easily mounted and rotated, but the roller tends to migrate axially along the shaft under belt forces

Engineering Contradiction:

Improveease of mounting and rotationVSAvoidaxial position stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The bore hole is designed with an asymmetric nonlinear shape that is symmetric about a diameter perpendicular to the shaft axis. This asymmetric geometry creates corresponding asymmetric contact points on the shaft that generate counteracting friction forces, preventing axial migration while allowing free rotation. The nonlinear shape breaks the symmetry that would otherwise allow axial movement.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The bore hole employs curved surfaces including arcs and circular segments rather than straight cylindrical walls. The curved geometry creates variable contact points with the shaft as the roller attempts to move axially, generating friction forces that resist migration. The circular arc portions specifically designed with radii create predictable friction force vectors that counteract axial movement tendencies.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Stability of the object's composition

If shaft clamps or hose clamps are used to prevent roller migration, then axial position stability is improved, but the solution becomes expensive and labor-intensive to install

Engineering Contradiction:

Improveaxial position stabilityVSAvoidinstallation complexity and cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The nonlinear bore hole geometry itself provides the migration prevention function without requiring additional clamps, clips, or fastening devices. The curved surfaces and asymmetric shape create self-generating friction forces that automatically constrain axial movement. This eliminates the need for separate retention components and their associated installation labor and costs.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The migration prevention function is merged into the bore hole geometry itself rather than being a separate feature. The nonlinear shape combines the mounting function and the axial constraint function into a single integrated structural element, eliminating the need for separate retention mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If spring-tension clips are used to prevent roller migration, then axial position stability is improved, but lateral pressure from the roller releases the bite of the dip on the shaft and allows the roller to push the dip along

Engineering Contradiction:

Improveaxial position stabilityVSAvoidretention reliability under lateral pressure

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The curved surfaces with specific radii create contact geometry that generates friction forces resistant to lateral pressure. The circular arc portions maintain consistent contact with the shaft under load, preventing the roller from pushing the mounting feature along the shaft axis.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The asymmetric nonlinear shape creates corresponding asymmetric friction force vectors that counteract lateral pressure from the belt. The geometry ensures that friction forces are generated in directions that prevent both axial migration and lateral displacement under operational loads.

Inventive Principle:

Principle #4Asymmetry

4Stability of the object's composition

If duct tape is used to prevent roller migration, then axial position stability is improved, but the solution is not aesthetically pleasing

Engineering Contradiction:

Improveaxial position stabilityVSAvoidaesthetic appearance

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The nonlinear bore hole provides an integrated, permanent solution that eliminates the need for temporary or cosmetic fixes like duct tape. The engineered geometry provides both functional retention and a clean, professional appearance as part of the roller's structural design.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11021330B2Roller with nonlinear bore hole in a conveyor system

Publication Date: 2021.06.01 LAITRAM LLC

AI summary

A roller for a conveyor system comprises a nonlinear bore hole to facilitate retention of the roller on a roller-receiving portion of a corresponding shaft. A nonlinear bore hole comprises a central cylindrical portion for receiving a roller-receiving portion of the shaft and unaligned slots in communication with the central cylindrical portion to prevent migration of the roller from the roller-receiving portion.