Modular Conveyor Roller System with Interchangeable Motor Units
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Solution Overview
Problem
Existing motor-driven conveyor rollers face challenges with interchangeability, complex design, and high storage costs due to non-standardized geometric and performance dimensions, making replacement and adaptation difficult, especially in applications requiring quick spare parts delivery.
Innovation Solution
A modular system with standardized components, including different electric motors and gear modules, allows for customizable conveyor rollers with adaptable torque and speed, enabling production of various variants with additional functions like braking energy recovery and sensory capabilities, reducing production and storage complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If motor-driven conveyor rollers are designed with different geometric dimensions and performance data to meet various application requirements, then adaptability and versatility are improved, but device complexity and storage costs increase
Solution Approach 1:
The conveyor roller is divided into separate modular components: a standardized roller shell and interchangeable motor units. The motor unit contains the electric motor, gearbox, and all torque transmission elements. This segmentation allows the roller shell to remain standardized while adapting to different applications by simply changing the motor unit, thereby maintaining versatility without increasing overall system complexity.
Solution Approach 2:
The standardized roller shell is designed with universal mounting interfaces and torque support structures that can accommodate different motor units. The torque support elements are integrated into the roller shell in a way that provides universal torque transmission capability, allowing the same shell to work with various motor configurations for different application requirements.
2Adaptability or versatility
If multiple variants of motor-driven conveyor rollers are produced to meet different conveying speeds and torque requirements, then adaptability is improved, but manufacturing complexity and storage requirements increase
Solution Approach 1:
The product line is segmented into a common roller shell platform and standardized motor units. The roller shell is manufactured once as a standardized component, while motor units are produced in standardized configurations. This segmentation allows the manufacturing of the roller shell to be simplified and standardized, reducing manufacturing complexity despite offering multiple variants.
Solution Approach 2:
Different conveyor roller variants are achieved by changing parameters within standardized components rather than creating entirely different designs. The roller shell maintains standardized dimensions and interfaces, while motor unit parameters (power, speed, torque) are varied within a standardized platform, allowing for easy manufacturing of different variants.
3Ease of manufacture
If conveyor rollers are designed with standardized interfaces and modular components, then ease of manufacture and interchangeability are improved, but design flexibility may be limited
Solution Approach 1:
The standardized roller shell incorporates universal torque support elements and mounting interfaces that provide adaptability within the standardized platform. The torque support elements are designed to work with various motor units while maintaining standardized interfaces, ensuring that standardization does not compromise the ability to meet different application requirements.
Solution Approach 2:
The modular design allows for dynamic configuration of the conveyor system by assembling different standardized components. The roller shell, motor units, and torque transmission elements can be dynamically combined in different configurations to meet specific application needs, maintaining design flexibility through modular assembly rather than fixed design.
4Ease of repair
If quick replacement of conveyor rollers is enabled through modular design, then ease of repair and downtime reduction are improved, but production costs may increase
Solution Approach 1:
The modular design segments the conveyor roller into easily separable components with standardized interfaces. The motor unit can be quickly removed and replaced from the standardized roller shell without complex disassembly, enabling quick replacement and repair. This segmentation facilitates ease of repair while keeping production costs manageable through standardized manufacturing processes.
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
The modular system enables the production of conveyor rollers that meet specific requirements, ensuring compatibility and long service life while minimizing storage needs and production costs, allowing for quick adaptation to changing demands and regional standards.
Implementation Method 1
an electric motor arranged in the conveyor roller tube, which is mechanically coupled between the second axle unit and the conveyor roller tube to generate a torque between the conveyor roller tube and the second axle unit
Implementation Method 2
a first bearing unit at the first end and a second bearing unit at the second end, about which the conveyor roller tube is rotatably mounted around the first and second axle unit
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a module system of motor-operated conveying rollers, comprising: a conveying-roller tube, a first axle unit, which is inserted into a first end of the conveying-roller tube, a second axle unit, which is inserted into a second end, opposite the first end, of the conveying-roller tube, a first mounting unit at the first end and a second mounting unit at the second end, about which the conveying-roller tube is mounted so as to be rotatable in a corresponding manner about the first and second axle units, an electric motor arranged in the conveying-roller tube, said motor being mechanically coupled between the second axle unit and the conveying-roller tube in order to generate a torque between the conveying-roller tube and the second axle unit. The module system comprises, as electric motor, a motor of a first type, which is coupled to the conveying-roller tube via a first interface and to the second axle unit via a second interface, and a motor of a second type different than the first type, which is coupled to the conveying-roller tube via the first interface and to the second axle unit via the second interface.