Modular Deflection Unit for Conveyor Weighing
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Solution Overview
Problem
Existing deflection units with larger roller diameters for heavy loads result in a larger transfer gap, leading to issues with the transfer of smaller products and disrupting weighing processes, especially in dynamic weighing scenarios where measurement time is short.
Innovation Solution
A modular deflection unit composed of multiple shorter roller modules arranged end-to-end, which are easily replaceable and adjustable, allowing for flexible conveyor widths and reduced transfer gaps without the need for re-adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If larger diameter rollers are used for heavy loads, then the bending strength of the transport belt is sufficient, but the transfer gap becomes larger causing products to fall through and disrupting weighing processes
Solution Approach 1:
The deflection roller is segmented into multiple shorter roller modules arranged end-to-end. Each roller module has a shorter length than a conventional continuous roller, but when arranged in series, they collectively provide the necessary support span. This segmentation allows the transport belt to be deflected adequately for heavy loads while maintaining a smaller overall transfer gap at the ends of the roller assembly.
2Strength
If larger diameter rollers are used, then the transport belt has sufficient bending strength, but the measurement time for dynamic weighing becomes excessively short or impossible
Solution Approach 1:
By segmenting the deflection roller into multiple shorter modules, the transfer gap is reduced, allowing products to be transferred more smoothly and quickly onto the weighing belt. This reduces the time required for products to settle on the scale, enabling accurate dynamic weighing within the available measurement time window.
3Strength
If conventional deflection units with larger roller diameter are used, then heavy loads can be handled, but retrofitting to reduce transfer gap requires readjustment of transfer gap and causes idle times
Solution Approach 1:
The modular roller module design allows the deflection unit to be easily assembled and disassembled. When upgrading from conventional large-diameter rollers to the new modular design, the roller modules can be quickly installed without requiring readjustment of the transfer gap, as the modular design inherently provides the optimized gap configuration. This significantly reduces idle time during retrofitting operations.
Solution Approach 2:
The roller modules are designed to be easily replaceable and reconfigurable, allowing the deflection unit to be adapted to different conveyor widths and load requirements. This dynamic reconfigurability enables quick retrofitting without extensive readjustment procedures.
4Length of moving object
If smaller roller diameter is used, then the transfer gap is reduced for better product transfer, but the bending strength of the transport belt becomes insufficient for heavy loads
Solution Approach 1:
The solution combines smaller roller modules (providing smaller transfer gap) arranged in series to achieve the necessary support span for heavy loads. The collective arrangement of multiple shorter rollers provides adequate bending support while each individual roller maintains a compact size that minimizes the transfer gap.
Data Source
AI summary
A modular deflection unit includes a supporting part extending in a transverse direction, at least one module support positioned along the supporting part and at least two roller modules. Roller axles of the roller modules are received and supported by the at least one module support such that the deflection unit as a whole can be modularly exchanged.