Modular Taper Cover Segments for Fast Conveyor Roller Assembly
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Solution Overview
Problem
The manufacturing and assembly process of existing tapered conveyor rollers is time-consuming and expensive.
Innovation Solution
A taper cover segment configured to fit circumferentially around a straight roller, featuring a main body with a frustum shape, ribs with claw-shaped edges for grip, cavities for weight adjustment, and a locking arrangement for detachable connection, allowing for efficient assembly and operation on conveyor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional tapered conveyor rollers are manufactured and assembled using existing processes, then the conveyor system achieves functional operation, but the manufacturing and assembly process is time-consuming and expensive
Solution Approach 1:
The conveyor roller is divided into modular components: a straight roller core and separate taper cover segments. Each taper cover segment is a discrete piece that can be manufactured independently using standard machining processes, eliminating the need for complex tapered roller manufacturing. The segments are assembled onto the straight roller using a locking arrangement, significantly reducing assembly time and manufacturing complexity while maintaining the tapered functional geometry.
2Productivity
If taper cover segments are designed with locking arrangements for detachable connection, then assembly efficiency is improved, but device complexity increases
Solution Approach 1:
The locking arrangement integrates multiple functions into a unified mechanism. The locking arrangement simultaneously secures the taper cover segment to the straight roller, maintains the tapered geometry alignment, and provides a detachable connection interface. This merging of functions reduces the number of separate components needed while achieving efficient assembly and disassembly.
3Reliability
If ribs with claw-shaped edges are added to provide grip, then friction is reduced and durability enhanced, but manufacturing complexity increases
Solution Approach 1:
The ribs with claw-shaped edges are localized features on the taper cover segment inner surface. These ribs are positioned specifically where contact with the straight roller occurs to provide grip and reduce friction. The爪-shaped (claw-shaped) geometry is a simple form that can be created using standard machining operations such as milling or shaping, adding minimal complexity to the manufacturing process while significantly improving durability through enhanced grip.
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
Enhances durability, reduces friction, and stabilizes the conveyor system by distributing weight unevenly to decelerate rotational movement, thereby improving efficiency and reducing assembly time and costs.
Implementation Method 1
a center of mass of the taper cover segment is offset from the longitudinal axis
Implementation Method 2
Each rib has a claw shaped edge that is configured to provide a grip between the rib and the straight roller
Implementation Method 3
a locking arrangement that is monolithic with a first end of the main body. Further, the locking arrangement is configured to detachably connect the taper cover segment with another taper cover segment
Data Source
AI summary
A taper cover segment configured to fit circumferentially around a straight roller is disclosed. The taper cover segment comprising a main body having an inner surface and an outer surface, a plurality of ribs that are monolithic with the main body and extend radially inward from the inner surface of the main body. Each rib has a claw shaped edge that is configured to provide grip between the rib and the straight roller. A plurality of cavities is defined between adjacent ribs of the plurality of rib. A locking arrangement is monolithic with a first end of the main body, and is configured to detachably connect the taper cover segment with another taper cover segment to form a taper cover for encasing the straight roller. The taper cover segment defines a longitudinal axis, and a center of mass of the taper cover segment can be offset from the longitudinal axis.