Modular Conveyor Roller Axle Assembly for Fast Variant Production
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Solution Overview
Problem
The existing methods for producing conveyor rollers require a large inventory of different axle parts and involve time-consuming assembly processes, making it inefficient to produce rollers in various configurations.
Innovation Solution
A modular axle design comprising interchangeable axle elements, such as a first axle element with a cavity and a second axle element that fits within the cavity in a force-fitting, form-fitting, or material-locking manner, allowing for quick assembly and easy configuration changes without interrupting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a wide variety of axle parts are stocked to manufacture conveyor rollers in various configurations, then different roller designs can be produced, but storage space requirements increase significantly
Solution Approach 1:
The axle is divided into multiple interchangeable elements (axle center tube, axle stubs, adapters) that can be combined in different configurations. This segmentation allows a limited set of standardized components to create multiple axle variants, reducing the need to stock numerous complete axle assemblies while maintaining the ability to produce diverse conveyor roller designs.
Solution Approach 2:
The axle elements are designed with universal interfaces and standardized features that allow the same components to serve multiple functions and configurations. For example, adapters can accommodate different axle stub types, and the modular design enables the same base elements to be used across various axle lengths and configurations, reducing inventory requirements.
2Adaptability or versatility
If a wide variety of axle parts are stocked to manufacture conveyor rollers in various configurations, then different roller designs can be produced, but preparation time for required axles increases
Solution Approach 1:
By segmenting the axle into standardized, interchangeable elements, the system enables rapid assembly of different configurations from a common pool of components. This eliminates the need to retrieve and prepare complete pre-assembled axles for each configuration, significantly reducing preparation time while maintaining design flexibility.
Solution Approach 2:
The axle elements are pre-manufactured with standardized interfaces and features during production. This preliminary preparation of individual components allows for rapid final assembly when specific configurations are needed, as the elements are already prepared and compatible, eliminating time-consuming on-site fabrication or modification.
3Adaptability or versatility
If a wide variety of axle parts are stocked to manufacture conveyor rollers in various configurations, then different roller designs can be produced, but final assembly time increases
Solution Approach 1:
The modular segmented design of the axle allows individual elements to be independently prepared and then quickly assembled in different sequences and configurations. This segmentation enables parallel preparation of components and simplifies the final assembly process, reducing overall assembly time while maintaining the ability to create various roller designs.
Solution Approach 2:
The axle elements are designed to nest within each other (axle stubs within adapters, adapters within the axle center tube), creating a hierarchical assembly structure. This nesting design simplifies the assembly process as elements are inserted in a predetermined sequence with standardized interfaces, reducing the complexity and time of final assembly compared to joining multiple separate components.
4Productivity
If automated assembly of individual axle elements is implemented, then production rate increases, but the complexity of the assembly system increases
Solution Approach 1:
The segmented modular design of the axle creates discrete, standardized elements that are ideally suited for automated handling and assembly. Each element can be independently fed, positioned, and joined by automated equipment, enabling high production rates. The standardization of interfaces reduces the programming and control complexity compared to assembling custom-fit components.
Solution Approach 2:
The universal interfaces and standardized features across all axle elements allow a single automated assembly system to handle multiple configurations without requiring complex retooling or reprogramming. The same assembly equipment can accommodate different axle stubs, adapters, and center tubes through standardized positioning and joining mechanisms, reducing system complexity while maintaining versatility.
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
This design enables efficient production with minimal storage requirements, allows for various configurations, and facilitates automated assembly, reducing assembly time and enabling quick implementation of customer-specific requirements.
Implementation Method 1
the second axle element is arranged at least partially in the hollow space of the first axle element and is connected in the hollow space in a force-fitting, form-fitting and/or material-fitting manner to the first axle element
Implementation Method 2
the second axle element is arranged at least partially in the hollow space of the first axle element and is connected in the hollow space in a force-fitting, form-fitting and/or material-fitting manner to the first axle element
Data Source
Figure 1~2
Figure 3~5
AI summary
An axle (2) for a conveyor roller, comprising: a first axle element (6; 8); and a second axle element (4; 6); wherein: the first axle element (6; 8) has a cavity (10; 12) at least in the region of a free end; and the second axle element (4; 6) is arranged, at least in regions, in the cavity (10; 12) of the first axle element (6; 8) and is frictionally connected to the first axle element (6; 8).