Modular Roller Structure With Integrated Stop Portions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional roller structures and manufacturing methods are structurally intricate, leading to complex assembly processes and reduced production efficiency, and often fail to match other modular components, necessitating time-consuming independent manufacturing and assembly.
Innovation Solution
A modularized roller structure featuring a rotatable roller with integrated stop portions and a bush, allowing for efficient assembly and production, where the roller rotates between stop portions and is coupled to a load using various fixation mechanisms, enabling streamlined assembly and cost reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional roller structures are used, then the roller can carry loads, but the assembly structure becomes structurally intricate and the assembly process becomes complicated
Solution Approach 1:
The axial portion integrates multiple functions: it serves as the rotation axis, includes stop portions to limit roller rotation, and provides mounting features for the bush. This merging of functions into a single component reduces the number of separate parts and simplifies the overall assembly structure while maintaining load carrying capability
Solution Approach 2:
The axial portion is designed as a multi-functional component that simultaneously provides rotational support, rotational limitation through stop portions, and mounting interface for the bush. This multi-functionality reduces device complexity by eliminating the need for separate components for each function
2Ease of operation
If conventional roller structures are used, then the roller can rotate and reduce friction, but the assembly operation becomes time-consuming and production efficiency decreases
Solution Approach 1:
The stop portions are pre-integrated into the axial portion during manufacturing, eliminating the need for separate assembly steps to install rotational limiters. This preliminary integration of components directly improves assembly efficiency while preserving the roller's rotation function
Solution Approach 2:
Multiple components (axial portion, stop portions, bush mounting features) are merged into integrated structures that reduce the number of assembly operations required, thereby improving productivity without compromising the roller's ease of operation
3Reliability
If conventional roller structures are used, then the roller can function independently, but it fails to match other modular components requiring independent manufacturing and assembly
Solution Approach 1:
The axial portion is designed with standardized mounting interfaces and features that enable compatibility with modular components such as pivots and other standard hardware. This universal design allows the roller to function independently while also integrating seamlessly into modular assemblies, improving adaptability without sacrificing reliability
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 modularized roller structure enhances assembly efficiency, reduces production costs, and facilitates standardized module assembly, improving the overall efficiency and compatibility with other components.
Implementation Method 1
Rollers work efficiently, because of the relatively small friction between each rotating roller and its rail or a surface
Data Source
AI summary
A roller structure and a manufacturing method thereof are introduced. The roller structure includes a roller rotatable about an axial portion, an end of a bush is fixed to an end of the axial portion, and another end of the bush having an engaging portion coupled to a load, a first stop portion disposed at another end of the axial portion and the bush has a second stop portion positioned opposite to the first stop portion such that the roller rotates between the first stop portion and the second stop portion; wherein the engaging portion of the bush has a feeding space that receives a material of the load to couple the engaging portion to the load. Hence, the roller structure and the manufacturing method thereof provide a modularized roller structure for carrying a load, effectuate modularized assembly and production, enhance assembly efficiency, attain structural streamlining, and cut costs.