Interdigitating Multi-Piece Conveyor Rollers
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Solution Overview
Problem
The manufacturing of roller-top conveyor belt modules with steel axles is complex and labor-intensive, requiring either injection-molding around a roller or a secondary step to assemble and weld the roller and axle within the module.
Innovation Solution
A multi-piece roller design comprising first and second interdigitating roller sections that fit together to form a complete roller, with interdigitating members preventing axial separation, allowing for simplified assembly and integration with the axle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If injection-molding is used to manufacture roller-top modules with steel axles, then the roller and axle can be integrated into the module, but the manufacturing process becomes more complex and labor-intensive
Solution Approach 1:
The roller is divided into two separate sections that can be manufactured independently and then assembled together with the steel axle. This segmentation allows each component to be optimized for its specific manufacturing process, reducing overall manufacturing complexity while maintaining integration.
Solution Approach 2:
The roller sections are assembled by sliding them together in a direction perpendicular to the central axis of the roller, creating a multi-dimensional assembly approach. This allows the roller to be constructed from separate pieces that fit together radially, simplifying the integration process compared to traditional single-piece molding.
2Productivity
If a secondary manufacturing step is used to assemble roller and axle, then the roller-top module can be manufactured, but the process requires additional welding or retention steps
Solution Approach 1:
The roller is segmented into two sections with interdigitating members that interlock with each other, eliminating the need for welding or additional retention steps. The interdigitating design allows for simple mechanical assembly while maintaining structural integrity.
Solution Approach 2:
The two roller sections are combined through interdigitating members that interlock together, merging the functions of both sections into a single integrated roller assembly. This combining approach simplifies the overall assembly process by eliminating separate retention mechanisms.
3Reliability
If interdigitating members are used to prevent axial separation, then the roller sections remain securely assembled, but the roller design becomes more complex
Solution Approach 1:
The roller is segmented into sections with interdigitating members that provide secure mechanical interlocking. This segmentation with interlocking features ensures reliable assembly stability while maintaining a relatively simple overall design compared to traditional single-piece rollers.
Solution Approach 2:
The interdigitating members act as intermediary elements between the two roller sections, providing a mechanical connection that prevents axial separation. These intermediary features simplify the design by using straightforward interlocking geometry rather than complex fastening mechanisms.
Data Source
AI summary
Multi-piece rollers for a conveyor belt. First and second roller sections fit together to form a complete roller. The two roller sections together define a bore for receiving an axle. The bore and the periphery of the roller are formed in part by each of the first and second roller sections. The roller is assembled by sliding the two sections together in a direction perpendicular to the axle with the bore closing around the axle. The roller sections have fingers that interdigitate with each other to prevent axial separation of the first and second roller sections. The interdigitated fingers surround a majority of the bore.