Modular Conveyor Drive Assembly for Customization Without Rework
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Solution Overview
Problem
Conventional drive assemblies for conveyor devices are costly and time-consuming to produce due to high customization requirements, leading to high production expenses and long lead times.
Innovation Solution
A standardized modular drive assembly comprising a gear unit module and a motor module with a torque link, allowing for interchangeable connections and standardized interface measurements, enabling the production of customized drive assemblies with a small number of parts and reducing production costs and lead times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional drive assemblies are customized for each customer requirement, then special customer requirements can be satisfied, but production costs and lead times increase significantly
Solution Approach 1:
The drive assembly is divided into separate modular components: a motor module and a gear unit module, each with standardized interfaces. This segmentation allows independent manufacturing and assembly of standardized modules, enabling high-volume production of individual modules while maintaining the ability to create customized combinations for different customer requirements.
Solution Approach 2:
The motor module and gear unit module are designed with universal standardized interfaces that can accommodate multiple configurations. The base plates feature standardized mounting patterns and connection points that work across different module combinations, allowing the same basic modules to serve multiple applications and customer specifications.
2Adaptability or versatility
If conventional drive assemblies are customized for each customer requirement, then special customer requirements can be satisfied, but production costs increase
Solution Approach 1:
By segmenting the drive assembly into standardized motor and gear unit modules, each module can be manufactured in high volumes using standardized processes. This economies-of-scale approach reduces per-unit production costs while the modular interface system maintains customization capability through different module combinations.
Solution Approach 2:
The system uses standardized interface parameters and dimensions that define how modules connect and interact. By maintaining fixed parameter standards while allowing variable module selections, the system achieves customization without requiring custom manufacturing for each configuration, thereby controlling production costs.
3Device complexity
If conventional drive assemblies use a single-piece base plate design, then structural simplicity is maintained, but flexibility and adaptability are reduced
Solution Approach 1:
The single-piece base plate is segmented into separate motor module base plate and gear unit module base plate, each with standardized mounting interfaces. This segmentation enables modular assembly while the standardized interface patterns maintain structural coherence and simplify the design of individual modules.
Solution Approach 2:
The base plate connection system incorporates vertical stacking capability through standardized mounting surfaces and heights. Modules can be arranged in different vertical configurations while maintaining structural integrity, adding a dimensional aspect to the modular assembly that enhances adaptability without complicating individual module design.
Data Source
AI summary
A standardized modular drive assembly includes: a gear unit module, which includes a gear unit mounted on a gear unit base plate, the gear unit having an output shaft which is adapted to be coupled with a conveyor device pulley shaft; and a motor module, which includes an electric motor mounted on a motor base plate, the motor base plate being able to be joined and connected to the gear unit base plate in an exchangeable manner, and the motor module having a torque link which is adapted to be coupled with a conveyor device support structure.