Modular Conveyor Roller Axle Support for Backline Pressure Reduction
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Solution Overview
Problem
Modular conveyor belts face challenges in reducing backline pressure when accumulating products, particularly with high friction items that can damage the belt, and existing solutions like rotatably mounted rollers are cumbersome to assemble and result in undesirable pin wear.
Innovation Solution
A modular conveying assembly with roller axle supports extending above the top surface of the conveyor modules, allowing a roller axle to span across modules for easy replacement and reduced friction, featuring interchangeable rollers that minimize damage and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If rollers are rotatably mounted directly on the hinge pin connecting modules together, then backline pressure is reduced, but the roller assembly becomes complex and pin wear increases
Solution Approach 1:
The roller support system is segmented into separate components: the hinge pin remains distinct from the roller support structure. Roller support brackets are attached to adjacent modules, creating separate functional elements that avoid the complexity of integrated hinge-roller assemblies while still achieving roller rotation for backline pressure reduction
Solution Approach 2:
Roller support brackets serve as intermediary components between the hinge pin and the rollers. These brackets provide mounting surfaces for rollers without requiring the hinge pin itself to support the rollers, thereby reducing pin wear while maintaining the backline pressure reduction benefit
2Stress or pressure
If large diameter rollers are used to engage objects being conveyed, then backline pressure is reduced, but the roller extends both above and below the module when not always desired
Solution Approach 1:
The roller support brackets are designed with specific local geometries that allow rollers to be positioned at optimal heights for engaging conveyed objects. The brackets can be configured with different extension heights above the module top surface, providing local customization of roller position without requiring large diameter rollers that extend below the module
3Loss of energy
If rollers are supported by roller cradles between modules, then friction is reduced, but assembly becomes difficult requiring insertion of axles through holes in cradle walls
Solution Approach 1:
Instead of inserting axles through holes in cradle walls as in conventional designs, the invention inverts the assembly sequence by first positioning the roller on the support bracket and then securing it with fasteners from the accessible top side. This reversal of assembly logic eliminates the need for difficult side-ward or bottom-ward fastener installation
4Loss of energy
If rollers are supported by roller cradles, then friction is reduced, but the axle must be secured to prevent it from slipping out, increasing assembly complexity
Solution Approach 1:
The axle securing function is extracted from the roller support structure itself and implemented through separate, simple fastening elements. The support brackets include integrated fastening features that secure the axle without requiring complex retaining mechanisms, thereby reducing overall device complexity while maintaining low friction operation
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 solution effectively reduces backline pressure and allows for easy replacement of damaged components, enhancing the durability and efficiency of the conveyor system while preventing product damage.
Implementation Method 1
At least one roller is rotatably supported by the roller axle to reduce friction between the roller belt modules and an object carried along the conveyer belt assembly
Data Source
AI summary
A modular conveying assembly for reducing backline pressure when accumulating products includes a first roller belt module having a top surface and at least one first roller axle support extending above the top surface. The first axle support includes an opening. A second roller belt module adjacent to the first roller belt module has a top surface and at least one second roller axle support extending above the top surface. The second axle support includes an opening coaxial with the opening formed in the first roller axle support. A roller axle extends through the openings of the first and second axle supports. At least one roller is rotatably supported by the roller axle to reduce friction between the roller belt modules and an object carried along the conveyer belt assembly.