Conveyor Roller Reinforcement via Segmented Wall Thickness
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Solution Overview
Problem
Conveyor rollers in bulk material transportation systems face stability and deformation issues due to high loads, leading to increased energy consumption and production complexity, as existing reinforcement methods are costly and time-consuming.
Innovation Solution
The method involves producing a conveyor roller with a hollow-cylindrical shell reinforced internally by ironing a blank, which provides a one-piece roller body and axle shaft, reducing wall thickness variations and preventing deformation, thereby maintaining a straight outer surface and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the wall thickness of the roller shell is increased to ensure stability under load, then the stability and load-bearing capacity are improved, but the weight of the roller increases and production complexity increases
Solution Approach 1:
The roller shell is divided into different wall thickness sections: a reinforced middle section with greater wall thickness for stability, and thinner end sections for reduced weight. This segmentation allows the roller to achieve stability where needed without uniformly increasing weight and production complexity throughout the entire structure.
Solution Approach 2:
The roller shell has non-uniform wall thickness distribution, with the middle section having greater thickness for enhanced stability and load bearing, while the end sections have smaller thickness to reduce weight. This local variation in quality allows the structure to be optimized for stability without proportionally increasing overall complexity.
2Weight of moving object
If the wall thickness is reduced to decrease weight, then the weight and energy consumption are reduced, but the stability and resistance to deformation under load deteriorate
Solution Approach 1:
The roller shell is segmented into different wall thickness zones: thinner end sections reduce weight and energy consumption, while the reinforced middle section maintains stability and deformation resistance under load. This segmentation resolves the contradiction by applying different thickness characteristics to different functional zones.
Solution Approach 2:
The roller shell exhibits local quality variation with greater wall thickness in the middle section for stability and smaller wall thickness at the ends for weight reduction. This localized optimization allows the roller to achieve both low weight and high stability simultaneously.
3Stability of the object's composition
If reinforcing ribs are added to the roller shell to increase stability, then the stability is improved, but the production time and cost increase
Solution Approach 1:
The reinforcement structure is merged with the roller shell itself, forming a one-piece construction where the reinforced middle section is an integral part of the shell. This eliminates separate reinforcing ribs and their associated production steps, reducing production time while maintaining stability.
Solution Approach 2:
The reinforcement is built into the roller shell during the forming process itself, with the middle section having greater wall thickness from the outset. This preliminary integration of reinforcement avoids subsequent addition of separate reinforcing elements, reducing production time and complexity.
4Device complexity
If the roller shell is made as a one-piece structure to simplify production, then the production complexity is reduced, but the ability to provide targeted reinforcement deteriorates
Solution Approach 1:
The one-piece roller shell incorporates local quality variation through different wall thickness sections: the middle section has greater thickness for stability and load bearing, while the end sections have smaller thickness. This local differentiation is achieved within the single integrated structure, maintaining simplicity while providing targeted reinforcement.
Solution Approach 2:
The one-piece roller shell is segmented into different functional zones with varying wall thickness: a reinforced middle section for stability and thinner end sections for weight reduction. This segmentation is built into the single integrated structure, avoiding the need for separate reinforcement components while maintaining targeted stability where needed.
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 approach enhances the stability and wear resistance of the roller, reduces energy consumption by minimizing deformation-related energy loss, and lowers production costs by simplifying the manufacturing process, resulting in a more efficient and cost-effective conveyor system.
Implementation Method 1
the reinforcement is produced by ironing, in particular cold ironing, of a blank and the roller body is given its final external shape by ironing
Data Source
AI summary
The invention relates to a roller for a conveyor, especially a belt or a band conveyor, comprising a roller body (1) and an axle (2) mounted in at least two roller bearings (3). Said roller body (1) comprises a hollow cylindrical roller tube (6) comprising roller bearing seats (7) for the roller bearings (3) on the two outer end sections thereof. According to the invention, the roller tube (6) has a reinforcement (8) in the central section thereof.