Modular Sprocket Wheel Assembly for Fast Conveyor Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sprocket wheel systems for conveyor belts require frequent replacement and complex assembly, leading to downtime and increased costs due to the need for custom sprocket wheels for different conveyor belt constructions, and they often fail to maintain proper engagement with modular belt links, causing wear and noise.
Innovation Solution
A multi-part sprocket wheel system that allows in-situ assembly and replacement on the axle, using adapter members to maintain proper distance and engagement with modular belt links, reducing the need for multiple sprocket wheel sizes and enabling easy maintenance by allowing limited adapter members to fit various conveyor belt and axle constructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sprocket wheels are made as single-piece units, then manufacturing is simpler, but replacement requires dismantling the conveyor structure and assembly is more complex
Solution Approach 1:
The sprocket wheel is divided into a hub portion and a periphery portion with teeth, which can be assembled separately. The hub portion remains on the axle while the periphery portion can be replaced independently, enabling easy repair without complete dismantling while maintaining manufacturing simplicity for each component.
Solution Approach 2:
The periphery portion is designed to fit over the hub portion, with the hub nested within the periphery assembly. This nested structure allows the periphery to be attached to and removed from the hub without removing the entire sprocket wheel from the axle, facilitating quick replacement.
2Reliability
If multiple sprocket wheel sizes are used for different conveyor belt constructions, then engagement with various belt links is improved, but device complexity and inventory requirements increase
Solution Approach 1:
The hub portion is designed as a universal component that can accommodate different periphery portions with varying tooth configurations. This allows a single hub design to work with multiple periphery types, enabling the system to handle different conveyor belt constructions without requiring multiple complete sprocket wheel designs.
Solution Approach 2:
By separating the sprocket wheel into hub and periphery portions, the patent allows independent selection of periphery types to match different belt constructions. This segmentation enables versatility through modular periphery selection rather than requiring multiple complete sprocket wheel sizes.
3Strength
If periphery portions are assembled to hub portions using conventional fastening methods, then structural strength is improved, but assembly time and complexity increase
Solution Approach 1:
The periphery portion is pre-assembled with retaining arms that engage with the hub portion before final installation. This preliminary preparation allows for quick attachment to the hub without requiring complex fastening operations during assembly, reducing assembly time while maintaining connection strength.
Solution Approach 2:
The connection mechanism is segmented into retaining arms on the periphery that engage with corresponding features on the hub. This segmented fastening approach uses simple interlocking elements rather than multiple bolts or complex fasteners, achieving adequate strength with minimal assembly steps.
Data Source
Figure 1~2
Figure 3
Figure 4~7
AI summary
Multipart sprocket wheel adapted to engage modular belt modules in a conveyor belt, where said multipart sprocket wheel comprises: - two or more periphery elements, each element having an outer and and inner edge, where sprocket teeth are provided on the outer edge, and where the inner edge has an engagement surface, and where each element has means for being fastened to and adjacent periphery element, such that the two or more periphery elements outer edges forms a full circle; - one or more adapter members where each of said adapter members has an outer and an inner face, said outer face suitable to firmly engage the inner edge of one or more periphery elements, and said inner face adapted to engage a conveyor drive axle.