Axially Offset Gearmotor for Conveyor Roller Adaptability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conveyor systems with motor-driven rollers have limitations such as requiring multiple SKUs and roller lengths, limited torque density and speed ranges, and high costs, particularly due to increased demand from e-commerce and the need for accumulation conveyors.
Innovation Solution
A gearmotor assembly with an electric motor and gear train is directly connected to the conveyor roller, providing a rotatable motor output shaft that drives the conveyor roller through an axially offset train output shaft, allowing for efficient power transmission and adjustable torque and speed through intermeshing gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If motorized rollers are used in conventional conveyor systems, then power transmission is achieved, but the system requires numerous different SKUs and roller lengths to handle various packages
Solution Approach 1:
The gearmotor assembly with axially offset shafts is designed to provide universal power transmission capability that can accommodate different roller lengths and configurations through a single standardized design, eliminating the need for multiple specialized motorized roller SKUs while maintaining adaptability to handle various package sizes and types
2Power
If conventional motorized rollers are used, then basic driving power is provided, but torque density and speed ranges are limited
Solution Approach 1:
The invention merges the motor, gear train, and roller drive shaft into a single integrated gearmotor assembly where the motor output shaft is axially offset from the roller drive shaft. This combination allows the system to achieve high torque density through gear multiplication and extended speed ranges through direct motor control, while the integrated design reduces overall complexity compared to separate motor-roller assemblies
3Productivity
If motorized rollers are used to meet increasing e-commerce demand, then conveyor capacity is improved, but costs increase significantly
Solution Approach 1:
The standardized gearmotor assembly design provides universal applicability across different conveyor configurations and package handling requirements, allowing manufacturers to produce a single standardized component that can be deployed across multiple applications, thereby reducing per-unit costs through economies of scale while maintaining the productivity needed to handle increasing e-commerce volumes
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
This configuration enhances the conveyor system's ability to handle a variety of packages with improved torque density and speed ranges, reducing the need for multiple SKUs and lowering costs by providing a more efficient and versatile solution for material handling.
Implementation Method 1
a gear train drivingly connected to the motor output shaft. The gear train includes a train output shaft axially offset from the motor output shaft
Data Source
AI summary
A gearmotor assembly for use with a conveyor system has a rotatable conveyor roller extending laterally between spaced conveyor side rails. The gearmotor assembly includes an electric motor with a rotatable motor output shaft. The gearmotor assembly further includes a gear train drivingly connected to the motor output shaft. The gear train includes a train output shaft axially offset from the motor output shaft, with the train output shaft being drivingly connectable to the conveyor roller, so that rotation of the motor output shaft produces corresponding rotation of the conveyor roller.