Modular Hub Assembly for Roller Shaft Run-Out Reduction
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Solution Overview
Problem
Existing roller and shaft assemblies are often destroyed when components need replacement, leading to unnecessary replacement of the entire assembly, and current taper lock systems fail to maintain low run-out and allow for material compatibility, resulting in inefficiencies and material waste.
Innovation Solution
A modular hub assembly with tapered ends and bolt-on flanges allows for secure, non-destructive attachment and removal of shafts from the roller, enabling the use of different materials and reducing run-out through precision machining and self-centering alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional taper lock assemblies are used to secure rollers to shafts, then the shafts can be secured to the rollers, but it becomes impossible to maintain low roller to shaft run-out due to the pulling effect of the welding process and material incompatibility
Solution Approach 1:
The hub assembly is divided into separate components: a hub body that is press-fitted to the roller, and a separate locking mechanism with set screws. This segmentation allows the hub body to be precisely fitted to the roller without welding, maintaining low run-out, while the locking mechanism provides secure attachment. The separation of functions resolves the contradiction between precision alignment and material compatibility.
2Strength
If shafts and rollers are welded together or secured in press-fit arrangement, then the connection is strong, but the entire roller assembly must be replaced when a shaft or component needs replacement
Solution Approach 1:
The hub assembly is segmented into a hub body, locking mechanism, and shaft components. The hub body is press-fitted to the roller for strong connection, while the locking mechanism with set screws allows the shaft to be independently removed and replaced. This segmentation maintains connection strength while enabling easy repair by replacing only the shaft or locking mechanism components rather than the entire roller assembly.
Solution Approach 2:
The locking mechanism transitions from a static welded connection to a dynamic, adjustable connection using set screws and locking elements. This allows the shaft to be securely locked in position during operation, yet easily removed when maintenance is needed. The dynamic locking system resolves the contradiction between strong connection and ease of repair.
3Reliability
If full length shafts are used with conventional taper lock bushings, then the shafts can adequately function, but material waste occurs and the assembly has high degree of shaft deflection
Solution Approach 1:
The shaft is divided into a full-length functional portion and separate tapered end portions that fit into the hub assemblies. This segmentation allows the shaft to be precisely the length needed for functionality without extending beyond the roller ends, eliminating material waste. The tapered ends provide adequate functional performance while reducing overall material usage.
Solution Approach 2:
The shaft diameter and length parameters are optimized by using tapered end portions rather than full-length uniform shafts. This parameter change reduces material waste while maintaining adequate shaft function through the tapered geometry that provides proper fit and stress distribution in the hub assemblies.
4Ease of manufacture
If conventional prior art taper lock bushings are used, then shafts can be secured to rollers, but the materials must have the same tensile strength and full length shafts are required
Solution Approach 1:
The hub assembly separates the roller mounting function from the shaft locking function. The hub body can be made from materials optimized for roller attachment, while the shaft and locking mechanism can use materials optimized for their specific functions. This segmentation removes the constraint that all components must have the same tensile strength, enabling versatile material selection based on performance requirements rather than compatibility constraints.
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
Enables easy replacement of individual components without destroying the roller, reduces material waste, and maintains high bearing speeds with reduced deflection and vibration, allowing for flexible conversions between different shaft and bearing sizes.
Implementation Method 1
Each of the shafts has a tapered end which fits in direct contact with a tapered hole formed into respective ones of the roller flanges
Implementation Method 2
The roller flanges are have outward faces which are recessed to provide recesses surfaces which fit flush against respective ones of inward facing surfaces of the two shaft flanges to provide a friction engagement there-between
Implementation Method 3
Shaft flanges are provided for fixedly securing directly to respective ones of the two shafts, preferably with a press fit
Implementation Method 4
roller flange which is fixedly secured to the roller, usually by welding
Data Source
AI summary
A roller assembly (10) is provided having a roller (12) to which two shafts (14, 16) are fixedly secured by means of modular hub assemblies (18). The hub assemblies (18) each have a roller flange (20) which is fixedly secured to the roller (12), usually by welding. A shaft flange (26) is provided for fixedly securing directly to a respective one of the shafts (14, 16), preferably with a pressed fit. The shafts (14, 16) have tapered end sections (64) which fit in direct contact with tapered holes (32) formed into the roller flanges (20). The roller flanges (20 are further recessed to each provide a recessed surface (36) which fits flush against an inward facing surface (48) of the shaft flange (26) to provide a friction engagement there-between. The shaft flange (26) is preferably threadingly secured to the roller flange (20).