Gearless Direct Electric Drive Support Roll Stand
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Solution Overview
Problem
Conventional support roller frames for conveyor belt systems lack a robust and compact design with efficient power transmission, often resulting in slippage and reduced service life due to direct contact between rollers and belts, especially under varying loads and environmental conditions.
Innovation Solution
A support roller frame with a swivel frame design featuring at least two support rollers, one with a gearless direct electric drive, utilizing an external rotor motor with a hollow rotor connected non-rotatably to the roller, and a drive belt wrapping around the rollers to increase contact area and reduce wear, enabling synchronized control and efficient power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional support roller frames use direct contact between rollers and belts, then power transmission is simple, but slippage occurs and service life is reduced under varying loads
Solution Approach 1:
A drive belt is introduced as an intermediary element between the support rollers and the conveyor belt. The drive belt wraps around the support rollers and transmits power to the conveyor belt, eliminating direct contact and slippage between the rollers and the conveyor belt while maintaining efficient power transmission
2Power
If conventional rollers are used without direct drives, then the structure is simpler, but power transmission efficiency is reduced and slippage occurs
Solution Approach 1:
The electric motor and support roller are merged into a single integrated unit. The motor is mounted directly on each support roller, creating a self-contained drive unit that eliminates the need for separate drive mechanisms and complex power transmission systems while maintaining high power transmission efficiency
Solution Approach 2:
Traditional mechanical drive systems with gears, belts, and shafts are replaced with direct electric drives. Each support roller is equipped with its own electric motor, eliminating the need for complex mechanical power transmission components and reducing overall system complexity
3Duration of action of stationary object
If drive belts are introduced to wrap around rollers, then contact area increases and wear is reduced, but device complexity increases
Solution Approach 1:
The drive belt serves multiple functions simultaneously: it transmits power from the support rollers to the conveyor belt, increases the contact area between rollers and conveyor belt, reduces wear on both surfaces, and prevents slippage. This multi-functionality justifies the addition of the drive belt system
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 design enhances robustness and assembly efficiency, reduces slippage, increases service life, and maintains power transmission reliability under diverse conditions, including low loads and extreme temperatures, while allowing for decentralized braking and energy recovery.
Implementation Method 1
at least one of the conveyor rollers has its own gearless direct electric drive, with the drive being designed in each case as an external rotor motor with a hollow rotor non-rotatably connected to the roller
Implementation Method 2
a drive belt wrapping around the rollers to increase contact area and reduce wear, enabling synchronized control and efficient power transmission
Implementation Method 3
A support roller frame with a swivel frame design featuring at least two support rollers
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A support-roll stand for a belt conveyor system, comprising a pivoting frame (6), on which at least two support rolls (20, 21) are mounted, at least one of the support rolls (20, 21) mounted on the pivoting frame (6) being directly and gearlessly electrically driven.