Roller Conveyor Chain Freewheel Switching for Zone Control
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Solution Overview
Problem
Existing roller conveyors face challenges in easily and reliably switching the force transmission between the drive chain and conveyor rollers, leading to potential damage or injury from unintended forward transport of goods.
Innovation Solution
A roller conveyor design that allows the drive chain to transition between engaged and freewheeling positions through a switching element, enabling frictional connection control between the drive chain and pinions, with the drive chain moving transversely relative to its longitudinal direction, assisted by gravity, to facilitate smooth stopping and starting of conveyed items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the drive chain is constantly engaged with the pinions, then continuous conveying is achieved, but the ability to easily interrupt conveying and control individual sections is lost
Solution Approach 1:
The roller conveyor is divided into multiple independently controllable sections, each with its own switching device. This segmentation allows individual sections to be engaged or disengaged from the drive chain independently, enabling easy interruption of conveying in specific zones while maintaining operation in others. The switching devices are distributed along the conveyor, creating modular control zones.
Solution Approach 2:
The switching devices enable dynamic transition between engaged and disengaged states for each section. The switching elements can move between positions to either engage the drive chain with the pinions (for active conveying) or disengage them (for free-wheeling). This dynamic capability allows flexible control of conveying sections based on operational requirements.
2Reliability
If the conveyor rollers are lifted vertically away from the drive belt to interrupt conveying, then conveying is stopped, but the mechanism becomes complex and space-consuming
Solution Approach 1:
Instead of vertical lifting, the invention uses horizontal engagement/disengagement of the drive chain with the pinions. The switching devices move the drive chain laterally to either contact or clear the pinions, creating a simpler mechanical solution that achieves reliable interruption without complex vertical lifting mechanisms.
Solution Approach 2:
The switching device acts as an intermediary between the drive chain and the pinions. It controls whether the drive chain transmits force to the pinions by positioning itself between them, providing a simple and reliable method to interrupt conveying without directly moving the heavy roller assemblies.
3Ease of operation
If sensors trigger wheel carrier pivoting to move rollers from free-wheel to drive position, then conveying control is achieved, but the mechanical transmission becomes complex
Solution Approach 1:
The conveying line is segmented into multiple zones, each with independent switching devices controlled by sensors. This allows localized control of conveying sections without requiring complex coordinated transmission across the entire system. Each section operates independently, simplifying the overall control architecture.
Solution Approach 2:
The invention replaces complex mechanical transmission linkages with a simpler system where the drive chain directly engages or disengages from pinions through lateral movement. This eliminates the need for intermediate transmission elements like pivoting wheel carriers and complex gear mechanisms.
4Reliability
If the drive chain is moved transversely to disengage from pinions, then smooth stopping is achieved with minimal wear, but the switching mechanism complexity increases
Solution Approach 1:
The switching devices enable dynamic transverse movement of the drive chain relative to the pinions. This lateral displacement allows smooth engagement and disengagement without sudden impacts, reducing wear on the drive chain and pinions while achieving reliable force transmission control.
Solution Approach 2:
The drive chain's own flexibility and movement capability are utilized to achieve engagement and disengagement. The switching devices simply guide the drive chain into or out of contact with the pinions, allowing the drive chain itself to perform the switching action through its natural lateral movement, rather than requiring additional actuating mechanisms.
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 design ensures precise control over the conveyor's operation, minimizing wear on components, reducing malfunctions, and preventing unintended movement of goods, thereby enhancing operational efficiency and safety.
Implementation Method 1
the drive chain moving transversely relative to its longitudinal direction, assisted by gravity
Data Source
Figure 1a~2b
Figure 3~4
Figure 5a~5d
AI summary
The present invention relates to a roller conveyor (1) for conveying conveyed goods (2, 3, 4), in particular in the form of discrete load carriers, comprising a machine frame, a plurality of driveable, preferably elongated, cylindrical conveyor rollers (5), at least two guide elements, a plurality of pinions (7), at least one circulating drive chain (8) with which the pinions (7) can be driven, at least one drive device for driving the drive chain (8), at least one switching device (9) with which a force transmission between the drive chain (8) and the conveyor rollers (5) can be switched on and off, wherein the switching device (9) has at least one switching element (10) which is provided and configured to be transferred from a passive position to an active position and vice versa.In order to further develop the roller conveyor (1) in such a way that a force transmission between the drive chain (8) and the conveyor rollers (5) can be reliably switched on and off by means of the roller conveyor (1), it is provided according to the invention that by means of a transition of the switching element (10) from the active position to the passive position the drive chain (8) can be transitioned from an engagement position to a freewheel position and vice versa, wherein the drive chain (8) in the engagement position is engaged with several sprockets (7), so that a torque can be introduced by means of the drive device via the drive chain (8) into the sprockets (7) assigned to the switching element (10), and thus causes a rotation of the conveyor rollers (5) assigned to the switching element (10), and wherein the drive chain (8) in the freewheel position is disengaged from the sprockets (7) assigned to the switching element (10) and has a clear freewheel distance (22) to them.Furthermore, the present invention relates to a method for operating the roller conveyor according to the invention (1).