Modular Conveyor Belt Module With Quick-Swap Drive
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Solution Overview
Problem
Conventional conveyor belt replacement in production lines is time-consuming and requires stopping the entire production line, as existing solutions do not facilitate quick and easy module swapping.
Innovation Solution
A conveyor belt module with a body housing a deflection roller, another deflection element, a drive, mechanical, and electrical connection elements, and sensors, allowing for easy disconnection, removal, and reconnection of the module without halting the production line, enabling quick replacement of worn components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If conventional conveyor belt replacement methods are used, then the conveyor belt can be replaced, but the entire production line must be stopped and the process is time-consuming
Solution Approach 1:
The conveyor system is divided into modular sections, each with its own drive unit and deflection rollers. This segmentation allows individual modules to be replaced independently without stopping the entire production line, as the modular design enables quick disconnection and reconnection of specific segments while other sections continue operating.
Solution Approach 2:
The system incorporates movable deflection rollers and adjustable module positions that allow dynamic reconfiguration during operation. The deflection rollers can be quickly repositioned to accommodate belt changes, and the modular sections can be dynamically adjusted to maintain continuous material flow through the system during maintenance operations.
2Ease of repair
If the entire production line is stopped for conveyor belt replacement, then the belt can be replaced thoroughly, but production time is lost
Solution Approach 1:
By segmenting the conveyor into replaceable modules with self-contained drive units and belt sections, the system enables targeted replacement of only the worn components. This segmentation ensures thorough replacement of problematic sections while maintaining operational continuity in other areas, eliminating the need for complete system shutdowns.
Solution Approach 2:
The modular design allows spare conveyor modules to be pre-prepared and staged for immediate installation. This preliminary preparation of replacement components enables quick swap operations where the new module is ready to install the moment the old one is removed, minimizing downtime while ensuring complete replacement of worn components.
3Device complexity
If conventional conveyor designs are used, then the structure is simple, but the replacement process is complex and time-consuming
Solution Approach 1:
The conveyor is designed as a series of simple, identical modular sections with standardized interfaces. This segmentation maintains overall structural simplicity while dramatically improving replaceability, as each module can be independently removed and replaced without affecting the complexity of other sections. The modular architecture transforms a complex replacement process into a series of simple, repeatable swap operations.
Solution Approach 2:
The modular design creates universal sections that can perform multiple functions - each module can be used in different positions along the conveyor, and spare modules can be stored and quickly deployed. This universality simplifies the replacement process by allowing any module to replace any other, reducing the complexity of maintaining inventories of specialized parts and simplifying the replacement procedure itself.
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 rapid and efficient replacement of conveyor belt sections without stopping the production line, allowing for continuous operation and facilitating module repair, with a robust deflection mechanism minimizing wear and supporting parallel conveyor belts for enhanced application flexibility.
Implementation Method 1
The individual conveyor belt sections run around rotatable deflection rollers
Implementation Method 2
a drive for driving at least the deflection roller. The drive is arranged in the body
Implementation Method 3
several spaced sliding bushes are rotatably mounted on the deflection shaft
Data Source
Figure 1
Figure 2
AI summary
The module has a deflecting roller (22) and a deflecting shaft (26) rotatably mounted on a body (10), and a conveyor belt (12) guided to the shaft. A drive i.e. drive motor, is arranged in the body for driving of the roller. Mechanical and electrical connection elements e.g. bushing, connect modules with a conveyor system or production lines. Sensors e.g. radio frequency identification-reader, are arranged under the belt such that workpiece carriers (50) transported to the belt are detected by the sensors. Sliding bushings are made of plastic, metal coated with PTFE and/or graphite or bronze.