Roller structure
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Solution Overview
Problem
Conventional roller structures and manufacturing methods are complex, leading to inefficient assembly and production, and they often do not match other components, requiring separate manufacturing and assembly processes.
Innovation Solution
A modularized roller structure with a rotatable roller, bush, and stop portions, where the bush is coupled to a load using various mechanisms, allowing for streamlined assembly and production, and a manufacturing method involving injection molding and pressing processes to form stop components, enabling quick and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional roller structures are used, then the roller can carry loads and rotate, but the assembly structure becomes structurally intricate and the assembly operation becomes complicated
Solution Approach 1:
The roller structure is divided into distinct functional modules: the roller body, the bush with engaging portion, and the stop portions. This segmentation allows each component to be manufactured independently and assembled systematically, reducing the overall assembly complexity while maintaining structural integrity.
Solution Approach 2:
The bush component serves multiple functions: it provides structural support, enables load transfer through the engaging portion, and works with stop portions to limit roller rotation. This multi-functionality reduces the number of separate components needed, simplifying the overall assembly structure.
2Productivity
If conventional roller structures are used, then the roller can rotate and carry loads, but the production efficiency is compromised due to complicated assembly process
Solution Approach 1:
The bush and stop portions are designed to be pre-assembled or pre-positioned relative to the roller, with the bush's engaging portion ready to couple with the load before final installation. This preliminary arrangement of components streamlines the production process and improves efficiency.
3Adaptability or versatility
If conventional roller structures are used, then the roller can function independently, but it does not match other components for modularization requiring separate manufacturing and assembly
Solution Approach 1:
The engaging portion of the bush is designed with standardized features that can interface with various load types and other components in a modular system. This universal design enables the roller to be integrated into different modular assemblies without requiring custom manufacturing for each application.
Solution Approach 2:
By separating the roller, bush, and stop portions into distinct modular components with standardized interfaces, the design enables independent manufacturing of each module that can then be assembled into different configurations, improving adaptability while maintaining manufacturing efficiency.
Data Source
AI summary
A roller structure and a manufacturing method thereof are introduced. The roller structure includes a cylindrical roller rotatable about an elongated axial portion disposed coaxially in a through-hole of the cylindrical roller, a bush with an end fixed to an end of the elongated axial portion, the bush having a first stop portion positioned proximate to one axial end of the cylindrical roller and another end having an engaging portion coupled to a load, and a second stop portion disposed at an opposite end of the elongated axial portion and positioned proximate to the other side of the roller such that the roller rotates between the first stop portion and the second stop portion. 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.