Lightweight Polymeric Conveyor Roller Design
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Solution Overview
Problem
Conventional rollers used in conveyor systems, especially in aircraft, are heavy, prone to damage, and lack durability, leading to increased fuel consumption and maintenance costs due to their metal construction and hollow design, which allows for corrosion and debris entry, and requires frequent replacement.
Innovation Solution
The development of lightweight, monolithic polymeric rollers with internal and external lightening elements such as cavities and grooves that reduce weight without compromising structural integrity, featuring a resilient material for durability and ease of inspection, and incorporating a self-lubricating design to prevent corrosion and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal rollers are used, then strength and durability are improved, but weight increases leading to higher fuel consumption
Solution Approach 1:
The patent changes the material parameter from metal to polymeric material, fundamentally altering the density and weight characteristics while maintaining structural functionality. This material substitution enables weight reduction while preserving sufficient strength for conveyor operations.
Solution Approach 2:
The patent employs composite polymeric materials that combine multiple properties within a single material system, achieving both lightweight characteristics and mechanical durability. The composite structure allows optimization of strength-to-weight ratio specific to roller applications.
2Weight of moving object
If hollow rollers are used to reduce weight, then weight decreases, but susceptibility to denting and deformation increases
Solution Approach 1:
The patent modifies the structural parameters by transitioning from hollow to solid construction, and from metal to polymeric material. This dual parameter change achieves weight reduction through material density while maintaining dent resistance through the inherent toughness and elasticity of polymeric materials.
Solution Approach 2:
The polymeric material acts as a flexible, resilient shell that can absorb impact forces without permanent deformation. The material's elasticity allows it to flex under load and return to its original shape, preventing denting while maintaining structural integrity.
3Weight of moving object
If hollow rollers are used, then weight reduction is achieved, but foreign material entry and corrosion increase
Solution Approach 1:
The patent changes the structural parameter from hollow to solid construction, eliminating the internal cavity that would otherwise allow foreign material entry. It also changes the material parameter to polymeric materials that are inherently corrosion-resistant, addressing both weight and contamination concerns.
Solution Approach 2:
The solid polymeric rollers are designed as durable, maintenance-free components that resist degradation from environmental factors. Their corrosion resistance and structural integrity extend service life significantly, reducing replacement frequency despite the initial manufacturing investment.
4Strength
If metal rollers are used, then strength is improved, but corrosion and flaking occur leading to bearing failure
Solution Approach 1:
The patent changes the material parameter from metal to polymeric material, eliminating the galvanic corrosion and oxidation issues inherent to metal. The polymeric material does not flake or corrode, preventing contamination of bearing systems and maintaining reliability over extended periods.
Solution Approach 2:
The use of composite polymeric materials provides both the necessary mechanical strength and chemical inertness to prevent corrosion. These materials can be formulated with embedded lubricants or wear-resistant properties that further protect moving components from degradation.
5Ease of repair
If rollers are inspected for wear, then maintenance can be performed, but disassembly is required increasing maintenance time
Solution Approach 1:
The patent employs visual indicators such as color-coded wear rings or transparent sections that change appearance when wear thresholds are reached. This allows operators to assess roller condition at a glance without disassembly, enabling rapid maintenance decisions and reducing downtime.
Solution Approach 2:
The roller design incorporates self-indicating features that automatically signal wear or damage conditions. The polymeric material's transparency or embedded sensors provide continuous feedback on roller health, eliminating the need for manual inspection and disassembly while maintaining proactive maintenance capabilities.
Data Source
AI summary
A roller made lighter through the use of lightening elements. The inventive roller, with its lightening element(s), is lighter yet maintains its overall dimensions, is strong and durable enough to withstand the rigors of the transportation industry and/or is cost effective to produce and maintain. The lightweight roller may be part of a system having at least one operable roller unit, each roller unit having a roller, cylindrical in shape having a length and a diameter, and a center aperture extending through the length of the roller, an axel/shaft having a diameter sized to rotatably fit within the central aperture of the roller, the shaft further having a retention mechanism located upon the shaft ends and an elongate “U” shaped roller rack, the roller rack sized to extend the length of the roller and having a pair of upwardly extending arms located adjacent the ends of the roller, each arm end having an aperture sized to receive the respective shaft end and locate the shaft with the roller in a fixed location. The roller system has at least one roller, preferably more or all of the rollers, having internal and/or external lightening elements.