Internal Load Cell Idler Roller for Belt Weighing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing belt conveyor weighing systems are time-consuming to install and prone to component damage, leading to inaccurate measurements due to the need for sub-frames and external load cells that are susceptible to material impact and build-up.

Innovation Solution

An idler roller with a load cell mounted internally within a rotatable drum, eliminating the need for sub-frames and allowing for direct measurement of material weight without external components, and incorporating features like self-aligning bearings and a battery charger for self-sufficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If external load cells are used on sub-frames to weigh materials, then weight measurement capability is achieved, but the load cells are susceptible to damage from falling materials and accuracy diminishes due to material build-up

Engineering Contradiction:

Improveweight measurement accuracyVSAvoiddamage to load cells from falling materials

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The load cell is nested inside the hollow bore of the static shaft, placing the measurement component within the protective structure of the roller assembly rather than exposing it externally. This nesting protects the load cell from falling materials while maintaining measurement capability through the shaft's structural interface

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The static shaft acts as an intermediary structure that transfers the weight of materials on the belt to the load cell mounted on its bore. This intermediary arrangement allows indirect measurement while protecting the load cell from direct exposure to falling materials and material build-up

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If sub-frames with external load cells are installed to enable weighing, then weight measurement is achieved, but installation time increases and conveyor operation is disrupted

Engineering Contradiction:

Improveweight measurement capabilityVSAvoidinstallation time and conveyor downtime

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The load cell is integrated directly into the idler roller assembly by mounting it on the static shaft, merging the weighing function with the existing structural component. This eliminates the need for separate sub-frames and external installations, reducing installation time and operational disruption

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The static shaft serves multiple functions: it provides structural support for the roller assembly, acts as a mounting platform for the load cell, and serves as the measurement interface. This multi-functionality eliminates the need for additional sub-frame structures and reduces installation complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Strength

If multiple idler rollers are provided to support heavy materials, then belt sag is limited and support is improved, but the complexity of the conveyor system increases

Engineering Contradiction:

Improvebelt support capabilityVSAvoidnumber of idler rollers

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The load cell mounted on the static shaft changes the functional parameter of the idler roller from purely mechanical support to combined support and measurement. This allows a single modified roller to perform dual functions, potentially reducing the number of rollers needed while maintaining support capability

Inventive Principle:

Principle #35Parameter changes

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

Simplifies installation, reduces downtime, and protects load cells from damage, ensuring accurate and consistent weight measurements with reduced cabling and operational disruptions.

Implementation Method 1

a load cell mounted on the static shaft internal the rotatable drum

Methodology Applied

Scientific EffectLoad cell measurement:

Implementation Method 2

at least one bearing intermediate the shaft and the rotatable drum

Methodology Applied

Scientific EffectFriction reduction: Friction

Data Source

PatentEP2807458B1A weighing idler roller for a belt weighing application

Publication Date: 2021.09.22 HEARN MICHAEL JOHN

Figure 1
Figure 2
Figure 3

AI summary

This invention relates to an idler roller (1) for a belt conveyor and an idler roller assembly (41). The idler roller (1) comprises an elongate static shaft (3), a rotatable drum (5) mounted about and substantially surrounding the static shaft (3) and at least one bearing (7, 9) intermediate the shaft (3) and the rotatable drum (5). The idler roller (1) further comprises a load cell mounted on the static shaft internal the rotatable drum (5). The static shaft comprises a load cell section that is weakened relative to the remainder of the shaft. By having such an idler roller, the idler roller will have the means necessary to weigh the materials passing over a conveyor (65) supported by the idler roller thereby obviating the need for a sub frame and a lengthy installation of weighing idler roller assembly. Figure