Linked Disc Assembly with Ramp Mechanism for USDA Compliance
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Solution Overview
Problem
Existing food-grade chain and disk assemblies in tubular drag conveyors often fail to meet USDA safety standards, leading to contamination risks due to non-compliant materials and design features, which can result in foodborne illnesses.
Innovation Solution
A linked disc assembly for continuous chain tensioning in tubular drag conveyors with no metal-to-metal contact points, featuring alternating double ear disc members and open chain link design with a ramp mechanism for manual quick release, utilizing USDA-compliant materials like stainless steel and UHMW-PE to ensure sanitation and pathogen control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical fasteners and geometric features are used in chain and disk assemblies, then the assembly can be manufactured and assembled, but the design becomes non-USDA compliant and creates contamination hazards
Solution Approach 1:
The patent removes all metal-to-metal contact points and mechanical fasteners from the conveying area, extracting the harmful elements that cause contamination. The chain and disk assembly uses non-metallic materials (UHMW-PE, stainless steel with coatings) in the conveying area to eliminate metal dust generation and contamination hazards while maintaining structural integrity through alternative connection methods.
Solution Approach 2:
The invention employs composite material construction combining UHMW-PE (ultra-high molecular weight polyethylene) for disc members and chain links with stainless steel for structural components. This composite approach provides both the sanitation requirements (non-porous, easy to clean surfaces) and mechanical strength needed, while meeting USDA compliance by eliminating metal-to-metal contact in the food contact area.
2Object-affected harmful factors
If USDA-compliant materials like UHMW-PE and stainless steel are used for load bearing components, then contamination hazards are reduced, but stiffness and strength are compromised
Solution Approach 1:
The patent uses composite material construction combining UHMW-PE for disc members and chain links with stainless steel for structural components. This composite approach provides both the sanitation requirements (non-porous, easy to clean surfaces) and mechanical strength needed, while meeting USDA compliance by eliminating metal-to-metal contact in the food contact area.
Solution Approach 2:
The chain links are designed with arcuate (curved) geometry rather than straight rigid bars. This curvature provides structural efficiency and flexibility, allowing the chain to maintain strength while accommodating the tensioning and movement requirements of the drag conveyor system. The curved geometry distributes stresses more effectively throughout the UHMW-PE material.
3Productivity
If the chain pitch is maintained to correspond to driving sprocket pitch, then the conveyor operates correctly, but the chain and disk assembly becomes subject to load-induced fatigue
Solution Approach 1:
The patent incorporates dynamic flexibility into the chain and disk assembly through the flexible UHMW-PE material properties and the articulated connection between chain links and disc members. This allows the assembly to absorb and distribute cyclic loading stresses, reducing fatigue accumulation while maintaining the required pitch for proper sprocket engagement and conveyor operation.
Data Source
AI summary
A linked disc assembly for use in continuous chain tensioning assemblies in tubular chain drag conveyors, comprising link members and alternating double ear disc members. Each disc member comprises a disc plate and an ear member transversely projecting therefrom. Each ear member consists of an arcuate leg defining a channel extending parallel to the disc plate and hingedly engaged by a link member. Each open chain link member defines a spacing gap. Each ear member arcuate leg defines a transverse notch adjacent a corresponding disc plate, the notch sized and shaped complementarily to the link member gap so as to form a sliding ramp for manual guided quick release through passage of a link member.