Idler Wheel Frame Adjustment via Gear Rack Mechanism
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Solution Overview
Problem
Conventional idler wheel conveyor belt support assemblies require stopping and locking the conveyor belt to adjust the position of idler wheels, leading to inefficiencies and excessive downtime due to the lack of real-time feedback during tracking adjustments.
Innovation Solution
An adjustable idler wheel assembly with a sliding and pivoting mechanism, accessible from a location away from the conveyor belt, utilizing a gear rack and lever system to adjust the position of idler wheels while the belt is moving, allowing for real-time feedback and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the conveyor belt is stopped to adjust the position of idler wheels, then worker safety is improved, but conveyor productivity deteriorates due to excessive downtime
Solution Approach 1:
A telescoping adjustment tool with a gear mechanism serves as an intermediary device, allowing workers to adjust idler wheel positions from a safe distance away from the moving belt. The tool engages with the frame's adjustment mechanism through gear teeth interaction, transmitting mechanical force without requiring direct contact with moving parts
Solution Approach 2:
The adjustment mechanism incorporates a telescoping tool that can extend and retract, allowing the worker to position the adjustment gear at the appropriate distance from the belt. The mechanism enables dynamic adjustment during belt operation rather than requiring static shutdown conditions
2Measurement precision
If the conveyor belt is stopped for tracking adjustments, then real-time feedback is eliminated, but adjustment precision deteriorates due to lack of immediate verification
Solution Approach 1:
The adjustment mechanism allows the conveyor belt to continue operating during the adjustment process. The gear-based telescoping tool enables continuous belt movement while the worker makes incremental position adjustments, providing real-time visual feedback on tracking improvements without interrupting the useful action of material transport
Solution Approach 2:
The mechanism provides immediate visual feedback as the belt responds to adjustments in real-time. Workers can observe belt tracking changes continuously during the adjustment process, allowing for precise verification and fine-tuning without waiting for shutdown/startup cycles
3Ease of operation
If a hammer is used to pound on the frame for adjustment, then adjustment capability is improved, but worker safety deteriorates due to proximity hazards with moving belt
Solution Approach 1:
The manual hammering method is replaced with a gear-based mechanical adjustment system. The telescoping tool incorporates a gear that meshes with the frame's adjustment mechanism, providing controlled, precise mechanical force application without the need for impact tools or direct contact with moving parts
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
Enables real-time tracking adjustments of the conveyor belt without stopping the conveyor, reducing downtime and improving efficiency by allowing adjustments to be made while the belt is operational.
Implementation Method 1
one of the first foot and the base comprising a gear rack, the other of the first foot and the base other than said first foot and the base comprising a gear coupler positioned adjacent to the gear rack
Implementation Method 2
The adjustment mechanism comprises a gear rack coupled to one of the idler wheel supporting frame or to the base
Implementation Method 3
such as by using an adjustment tool comprising a lever
Implementation Method 4
utilizing a gear rack and lever system to adjust the position of idler wheels
Implementation Method 5
The first foot is slidably coupled to the base for movement relative to the base
Data Source
AI summary
An idler wheel support for a conveyor belt comprises a gear rack adjustment mechanism or for use in adjusting the position of one end portion an idler wheel supporting frame. The gear rack is provided at said one end portion of the frame, such as on a foot, or on a base to which the foot is slidably coupled. A tool comprising a gear is selectively positioned for pivoting on the foot or base that does not have the gear rack with the gear engaged with the gear rack. When so engaged, pivoting the gear shifts said one end portion of the frame and adjusts the angle of the frame relative to the longitudinal conveyor frame axis and adjusts the longitudinal tracking of the conveyor belt. The gear can be mounted on a lever and positioned for pivotal engagement with the gear rack to enable adjustment of the belt tracking while the belt is moving.