Conveyor Roller Assembly Rocker Frame Design
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Solution Overview
Problem
Existing roller assemblies for conveyor belts require high power to move due to internal friction, deformation, and roller rotation friction, and are difficult to maintain and replace without stopping the conveyor, especially in long systems handling bulk material.
Innovation Solution
A roller assembly with two inclined side rollers and two central rollers mounted on a rocker frame, allowing for easy assembly and disassembly while reducing the power required for movement by minimizing dimensional and mounting accuracy needs, and enabling replacement without stopping the conveyor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the distance between central rollers is increased to reduce undulating movement, then internal friction of bulk material is reduced, but the load on each central roller increases exponentially
Solution Approach 1:
The patent divides the single central roller into two separate central rollers mounted on a rocker frame. This segmentation distributes the bulk material load between two rollers instead of one, reducing the exponential load increase that would occur with larger spacing. The rocker frame allows each roller to carry approximately half the load while maintaining effective spacing to reduce undulating movement and internal friction.
Solution Approach 2:
The patent combines two central rollers into a single support assembly through a rocker frame mechanism. This merging allows the system to achieve the benefits of reduced spacing (lower internal friction) while distributing the load across two rollers. The rocker frame integrates both rollers into one functional unit that can be collectively supported by the side rollers.
2Stress or pressure
If two central rollers are mounted on a rigid support to reduce load on each roller, then the load and rotation friction are reduced, but the support requires high dimensional and mounting accuracy
Solution Approach 1:
The patent replaces the rigid support structure with a dynamic rocker frame mechanism. The rocker frame is capable of pivoting and adjusting its position, allowing the two central rollers to be supported without requiring precise dimensional accuracy or mounting tolerances. The side rollers support the rocker frame at its ends, and the frame naturally finds its equilibrium position, accommodating variations in manufacturing and installation.
Solution Approach 2:
The rocker frame acts as an intermediary between the rigid support structure and the two central rollers. Instead of directly mounting the rollers to a rigid support that would require high precision, the rocker frame mediates the connection, providing flexibility and tolerance for dimensional variations while still effectively supporting the rollers and distributing the load.
3Loss of energy
If rollers are mounted on rigid supports to reduce friction, then rotation friction is reduced, but replacement requires stopping the conveyor belt
Solution Approach 1:
The patent segments the support system into modular components: two independent central rollers, a rocker frame, and side rollers. This segmentation allows individual rollers to be replaced independently without affecting the entire support structure. The rocker frame design enables quick detachment and reattachment, allowing roller replacement while the conveyor belt remains operational.
Solution Approach 2:
The dynamic rocker frame mechanism allows for quick assembly and disassembly of the central rollers. The pivoting connection enables the rocker frame to be easily detached from the side rollers and reattached, facilitating rapid roller replacement without requiring the conveyor belt to be stopped, thus maintaining production continuity while keeping rotation friction low.
Data Source
Figure 1
Figure 1A~3
Figure 2
AI summary
The assembly in question, transversal to the displacement direction of the conveyor belt (CT), comprises two inclined side rollers (30) and two central rollers (40), each one of the rollers (30, 40) being mounted around a respective shaft (31,41). The shaft (31) of each side roller (30) has an upper end (31a) hinged to a respective support portion (PS) arranged on one side of the conveyor belt (CT), said shaft (41) of each central roller (40) having ends (41a) mounted on opposite sides (20a) of a rocker frame (20), each one of the opposite sides (20a) of the frame (20) having a median portion hinged, in a suspended way, at the lower end (31b) of the shaft (31) of a respective side roller (30).