Multipart Sprocket Wheel Assembly for Floating Conveyor Engagement
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Solution Overview
Problem
Existing sprocket wheel technologies face challenges in maintaining constant tension in plastic components, leading to failure over time, and require complex manufacturing processes, while also necessitating replacement of entire substructures when conveyor belt modules change, causing downtime and wear issues due to inability to 'float' on the drive axle.
Innovation Solution
A multi-part sprocket wheel system comprising periphery elements with sprocket teeth and adapter members that allow assembly on the axle without dismantling, enabling in-situ replacement and adjustment to fit various conveyor belt and axle constructions, with adapter members providing lateral movement to maintain proper engagement with modular belt links.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sprocket wheels are made from plastic components, then manufacturing complexity is reduced, but constant tension causes failure over time
Solution Approach 1:
The sprocket wheel is divided into two separate halves that can be assembled around the drive axle without constant tension on plastic components. This segmentation allows the plastic sprocket halves to engage the conveyor belt modules without being subjected to continuous tensile stress, thereby maintaining reliability while preserving ease of manufacturing through simple injection molding processes.
2Ease of operation
If sprocket wheels are assembled from two halves with clamping, then assembly around axle is enabled, but axial wandering occurs without sufficient holding force
Solution Approach 1:
The sprocket wheel is segmented into two halves that can be separately positioned on the drive axle and then joined together. This segmentation enables easy assembly around the axle without requiring the sprocket to be slid over the entire length of the axle. The two halves are then secured together to prevent axial wandering while maintaining the benefit of simple assembly.
Solution Approach 2:
The two separate sprocket halves are merged together through joining means (such as bolts or fasteners) to form a complete sprocket wheel. This merging provides sufficient holding force to prevent axial wandering and maintain stable engagement with the conveyor belt modules, while still allowing for relatively simple assembly and disassembly procedures.
3Reliability
If entire substructure is replaced when conveyor belt modules change, then proper engagement is ensured, but downtime increases
Solution Approach 1:
The sprocket wheel is segmented into two halves that can be independently removed from the drive axle. This segmentation allows for rapid replacement of the sprocket wheel when conveyor belt modules are changed, without requiring replacement of the entire substructure. The two halves can be quickly detached and reattached, ensuring proper engagement while minimizing downtime.
Solution Approach 2:
The sprocket wheel design allows for dynamic assembly and disassembly of the two halves around the drive axle. This dynamic capability enables quick adaptation when conveyor belt modules are changed, allowing maintenance personnel to rapidly replace sprockets without extensive downtime, while still ensuring proper engagement with the new belt modules.
4Stability of the object's composition
If sprocket wheels are fixed rigidly on axle, then lateral movement is prevented, but wear increases and engagement precision deteriorates
Solution Approach 1:
The sprocket wheel assembly allows for controlled lateral movement or 'floating' on the drive axle through the joining mechanism between the two halves. This dynamic capability enables the sprocket to self-adjust and maintain precise engagement with the conveyor belt modules, reducing wear while preserving lateral position stability through the constraint of the joining means.
Data Source
AI summary
A multipart sprocket wheel engages modular belt modules in a conveyor belt. Each multipart sprocket wheel has two or more periphery elements. Each element has an outer edge and an inner edge. Sprocket teeth are provided on the outer edge. The inner edge has an engagement surface. Each element has fasteners for being fastened to an adjacent periphery element. Two or more periphery elements' outer edges form a full circle. One or more adapter members are used. Each adapter member has an outer face and an inner face. The outer face firmly engages the inner edge of one or more periphery elements. The inner face engages a conveyor drive axle.