Modular Conveyor Roller Cartridge for Custom Length Assembly
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Solution Overview
Problem
Conveyor devices of varying lengths are difficult and costly to produce, especially for replacement or small-scale applications, as existing methods require a limited assortment of pre-defined lengths, making it inefficient for custom or short-length requirements.
Innovation Solution
A modular conveyor system using a prefabricated drive cartridge that can be combined with different lengths of drum tubes and axle stubs, allowing for the creation of conveyor devices of specific lengths through a manageable number of simple process steps, including cutting drum tubes and assembling axle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conveyor devices are produced in different lengths to meet various application requirements, then adaptability is improved, but device complexity and production cost increase
Solution Approach 1:
The conveyor device is divided into modular segments: a standardized drive cartridge and variable-length drum tube sections. This segmentation allows the drive cartridge to be reused across different configurations while only the drum tube length varies, reducing production complexity for multiple length variants
Solution Approach 2:
The drive cartridge is designed as a universal component that can be applied to drum tubes of different lengths. This multi-functionality allows a single drive cartridge design to serve multiple conveyor configurations, eliminating the need for customized drive units for each length variant
2Adaptability or versatility
If individual conveyor roller sizes are designed to meet custom length requests, then adaptability is improved, but manufacturing precision and production cost worsen
Solution Approach 1:
The system segments the conveyor into standardized drive cartridges and variable-length drum tubes. This allows custom lengths to be achieved by selecting and assembling pre-manufactured segments rather than manufacturing each unique length from scratch, reducing production effort while maintaining precision
Solution Approach 2:
Drive cartridges and drum tube segments are pre-manufactured to precise specifications and stored as inventory components. When a custom length is needed, these pre-manufactured components are simply assembled rather than manufactured anew, significantly reducing production effort and lead time
3Ease of manufacture
If a limited assortment of pre-defined conveyor lengths is offered, then production cost is reduced, but adaptability worsens
Solution Approach 1:
The conveyor system is segmented into standardized drive cartridges and interchangeable drum tube sections of various lengths. This segmentation enables a limited set of components to be assembled into multiple final configurations, achieving both cost efficiency and length variety
Solution Approach 2:
The drive cartridge is designed to be inserted into and nested within the drum tube structure. This nesting arrangement allows the standardized drive cartridge to accommodate multiple drum tube length variants, enabling a limited component assortment to produce diverse conveyor lengths
Data Source
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AI summary
The invention relates to a conveyor device (200, 300) for conveyor installations which convey containers, palettes and similar, or bulk material, comprising: a drum tube (202, 302) which extends along a longitudinal axis and has a first end (206, 306) and a second end (208, 308) lying opposite said first end; and an electrical drive unit (116) designed to exert a conveyor torque from a first axle (108) onto said drum tube; characterised by a drive cartridge comprising a cartridge tube (120) that is secured coaxially in said drum tube in a torque-resistant manner and a cover that is rotationally mounted on the first axle and covers one end of the cartridge tube, said electrical drive unit being arranged inside the cartridge tube, and the cartridge tube being secured coaxially inside said drum tube.