Gearless Conveyor Drive Alignment With Flexible Shaft Coupling
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Solution Overview
Problem
Existing conveyor drive systems with gearless motors require significant modifications to the conveyor installation and face challenges in achieving rapid and easy alignment of the motor with the pulley shaft, particularly in unfavorable ambient conditions.
Innovation Solution
A conveyor drive system with a gearless motor that includes a base frame supported by a support structure with first and second alignment portions and a coupling mechanism, allowing for multiple stages of alignment between the motor shaft and pulley shaft, including coarse and fine adjustments, and a flexible coupling to compensate for residual misalignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional conveyor drive systems with separate motor and gearbox are used, then the drive components can be independently replaced, but the overall device complexity and space requirements increase
Solution Approach 1:
The patent combines the motor and gearbox into a single integrated drive unit where the motor shaft is directly coupled to the gearbox input shaft. This merging eliminates the need for separate mounting of motor and gearbox, reduces the number of external connections, and simplifies the overall system architecture while maintaining the ability to replace the integrated unit as a modular component.
2Ease of manufacture
If traditional conveyor drive systems with separate motor and gearbox are used, then components can be independently replaced, but the space required for mounting increases
Solution Approach 1:
The motor and gearbox are merged into a single compact assembly that occupies less mounting space than two separate components. The integrated design allows the drive unit to be mounted in a single location on the conveyor frame, reducing the overall footprint and simplifying installation while maintaining component replaceability.
3Device complexity
If conventional belt conveyors are used, then the structure is simple, but material and energy losses occur during material transfer
Solution Approach 1:
The patent replaces the conventional stationary belt with a dynamic pan conveyor system where pans are attached to a moving chain. This dynamic system allows for more efficient material transfer by maintaining continuous contact between material and conveying surface, reducing spillage and energy losses while keeping the overall structure relatively simple.
4Productivity
If the conveyor system is designed for high productivity, then more drive power is required, but the motor shaft rotation speed becomes excessively high
Solution Approach 1:
The patent changes the gear ratio parameter of the gearbox to optimize the balance between productivity and motor speed. By selecting an appropriate gear ratio, the system achieves high conveyor throughput while maintaining the motor shaft rotation speed within reasonable limits, avoiding excessive speeds that would require additional speed reduction mechanisms.
Data Source
Figure 1~2
Figure 3
AI summary
A conveyor drive system (1) for an industrial conveyor installation comprises a pulley shaft (2); a gearless motor (20) comprising a motor shaft (22) and a motor housing having a mounting section (24); a base frame (10) for supporting the motor (20); a first alignment portion (31); a support structure (40); a second alignment portion (32); a connecting portion (50) connecting the base frame (TO) to the second support member (42); and a coupling (60) gearlessly coupling the motor shaft (22) to the pulley shaft (2 ) and compensating for misalignment betw een the motor shaft (22) and the pulley shaft (2).