Conveyor Roller Slip Assembly with Wave Washer Compliance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional accumulator conveyor systems face challenges with expensive and robust start-and-stop mechanisms due to densely packed heavy loads, leading to operational difficulties and wear on motors and drive systems, and existing clutches are not cost-effective or practical for most settings, especially when applying a light enough load for controlled slip.
Innovation Solution
A roller bed conveyor system with a slip assembly that includes a drive shaft, heat sink interface, thrust washer, and compliance device, allowing for controlled and efficient transfer of power with minimal wear, using a wave washer as the compliance device to balance forces and maintain consistent torque application across rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional robust start-and-stop mechanisms are used to handle densely packed heavy loads, then the conveyor can reliably stop and start loads, but the mechanism becomes expensive and complex
Solution Approach 1:
The invention divides the conveyor system into individual roller segments, each with its own clutch mechanism. Instead of using a single robust start-and-stop mechanism for the entire conveyor, each roller can independently engage and disengage from the drive belt, allowing localized control and reducing the complexity of any single mechanism.
Solution Approach 2:
The invention introduces dynamic engagement and disengagement of clutches on individual rollers. The clutches can automatically engage when a roller contacts a gate or stop mechanism and disengage when the gate moves away, eliminating the need for complex centralized control systems while maintaining reliable operation.
2Loss of energy
If light clutch pressure is applied to allow controlled slip, then wear on motors and drive systems is reduced, but the clutch may slip under normal operating conditions
Solution Approach 1:
The clutch mechanism is designed to dynamically adjust its engagement state based on operating conditions. During normal operation, the light spring pressure maintains a slight slip condition that reduces wear. When a roller contacts a gate or stop mechanism, the increased load automatically increases friction engagement, preventing slip and ensuring reliable load driving.
Solution Approach 2:
The invention changes the friction parameter dynamically through the spring-loaded clutch design. The spring pressure provides a baseline light engagement that allows slip and reduces wear, while the mechanical contact with gates or stop mechanisms increases the normal force and friction coefficient, ensuring sufficient grip when needed.
3Quantity of substance
If multiple heavy loads are densely packed on the conveyor, then live storage capacity is maximized, but the motor and drive system experience excessive wear
Solution Approach 1:
The invention segments the drive system so that each roller operates independently with its own clutch. This allows the conveyor to handle densely packed heavy loads by distributing the workload across multiple independent drive points, reducing the stress on any single motor or drive component.
Solution Approach 2:
The invention converts the potentially harmful effect of slip under heavy loads into a beneficial wear-reduction mechanism. The light spring pressure in the clutch allows controlled slip that protects the motor and drive system from excessive wear, while the mechanical engagement with gates ensures loads are still moved reliably.
4Loss of energy
If existing clutches are used on individual rollers, then controlled slip is achieved, but the system becomes too expensive and large for most settings
Solution Approach 1:
The invention uses simple, inexpensive clutch mechanisms on each roller that can be easily replaced if needed. The clutch design relies on basic spring-loaded friction surfaces rather than complex electromagnetic or hydraulic systems, making the overall system more cost-effective despite the distributed architecture.
Solution Approach 2:
By distributing simple clutch mechanisms across multiple rollers rather than using a single complex centralized system, the invention achieves controlled slip capability at a lower overall cost and smaller size suitable for most conveyor settings.
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 system provides a cost-effective and reliable solution for accumulator conveyor systems by minimizing wear on motors and drive systems, allowing for efficient and controlled slip, reducing operational costs, and maintaining consistent torque application across rollers, even under heavy loads.
Implementation Method 1
a compliance device located between the thrust washer and the drive shaft
Implementation Method 2
a heat sink interface between the elongated tube and the driveshaft and wherein the heat sink interface and the drive shaft are configured to selectively rotate relative to each other
Implementation Method 3
a thrust washer located between the drive shaft and the heat sink interface
Data Source
AI summary
A material handling system have the ability for the rollers to slip relative to the drive system, such as a roller bed conveyor used an accumulator conveyor system. The rollers include a slip assembly with a clutch surface, wherein the tube of the roller is configured to act as a heat sink.