Riveted X-Bar Conveyor Segments for Sag Reduction
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Solution Overview
Problem
Traditional ad hoc flex conveyors require a larger footprint and more equipment, increasing costs and reducing efficiency in product transfer systems, especially in limited retail warehouse spaces, due to their inflexible design and need for additional conveyors to operate effectively.
Innovation Solution
The development of an expandable conveyor system with riveted x-bars and leg plates allows for flexible conveyor segments that can be easily connected and adjusted, reducing the overall equipment footprint and enabling efficient product transfer by minimizing the distance products need to travel, thus improving transfer rates and reducing manpower requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional ad hoc flex conveyors are used, then product transfer can be achieved, but the equipment footprint is larger and costs increase
Solution Approach 1:
The conveyor system is divided into multiple telescoping segments that can be independently adjusted. Each segment contains rollers and structural components that can extend or retract relative to adjacent segments, allowing the overall conveyor length to be optimized for the specific application while maintaining a compact configuration when not in use.
Solution Approach 2:
The conveyor incorporates telescoping mechanisms that allow dynamic adjustment of the conveyor length and configuration. The segments can extend during operation to maximize product transfer distance and retract when not needed to minimize footprint, transforming the static conveyor into a dynamic, space-efficient system.
2Adaptability or versatility
If additional specialized conveyors are added to the system, then product transfer capabilities are enhanced, but system costs increase
Solution Approach 1:
The telescoping conveyor segments are designed to perform multiple functions within a single integrated structure. The same segments that provide product support and movement also enable curvature adaptation and length adjustment, eliminating the need for separate specialized conveyors for curve handling or extension that would traditionally be required.
Solution Approach 2:
Multiple conveyor functions are merged into the telescoping segment design. The structural framework, roller support system, and extension mechanism are combined into integrated segments that replace what would traditionally require multiple separate conveyor units, including curve conveyors and extension conveyors.
3Ease of operation
If conveyor segments are made more flexible for easy connection, then ease of operation improves, but structural strength may be compromised
Solution Approach 1:
The connection system is segmented into discrete coupling mechanisms at each segment interface. These modular connection points allow for tool-free or minimal-tool assembly and disassembly while maintaining full structural strength when engaged, resolving the contradiction between ease of operation and structural integrity.
Solution Approach 2:
The x-brace structures incorporate curved or angled geometries that provide mechanical advantage and load distribution. The riveted x-bar configurations create triangular truss structures that are inherently strong yet allow for controlled movement during connection, enabling easy assembly without compromising the load-bearing capacity of the finished structure.
Data Source
AI summary
The disclosure provides improved X-bars and end frames that can prevent or at least reduce sagging in conveyors, such as flexible conveyors. The improved X-bars and end frames are referred to as riveted X-bars and leg plates, respectively. An expandable conveyor system, an expandable conveyor segment, and a riveted assembly are disclosed. Expandable conveyor segments can be coupled together via a riveted assembly to form an expandable conveyor system. In one example, the riveted assembly includes; (1) a leg plate and (2) two riveted x-bars connected to the leg plate via at least one slot insert.