Roller Conveyor Gap Blocker with Resilient Legs for Pinch Point Prevention
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Solution Overview
Problem
Conveyor systems, particularly roller conveyors, face issues with gaps between conveying surfaces that can lead to hazards for workers, such as pinch points and object loss, as well as operational disruptions due to items falling through or becoming lodged between rollers.
Innovation Solution
A gap blocker system for roller conveyors, featuring an elongate body with upstream and downstream contact portions and resilient legs, positioned in the gap to inhibit object fall and reduce friction, while maintaining stability and preventing worker hazards by obstructing pinch points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If o-rings are used to transfer rotation between rollers, then rotation transfer is achieved, but pinch points are created that pose safety hazards to workers
Solution Approach 1:
The gap blocker serves as an intermediary component that blocks the gap between rollers, preventing objects from falling through while also blocking the pinch points created by o-rings. The blocker body with upstream and downstream legs positions itself to interrupt the hazardous area where o-rings create pinch points, thus eliminating the safety hazard while preserving the rotation transfer function.
2Adaptability or versatility
If gaps exist between rollers, then relative movement is permitted, but objects can fall through or become lodged causing operational disruptions
Solution Approach 1:
The gap blocker is segmented into multiple components: a body portion and multiple legs (upstream and downstream). This segmentation allows the blocker to adapt to the gap space while maintaining structural integrity. The legs can independently contact the rollers, permitting relative movement and rotation while the body portion blocks objects from falling through, thus maintaining operational continuity.
Solution Approach 2:
The gap blocker acts as an intermediary element positioned in the gap between rollers. It mediates between the need for roller movement and the need to prevent object loss. The blocker allows rollers to move and rotate while preventing objects from falling through the gap, thus maintaining operational reliability.
3Reliability
If gap blockers are positioned in the gap, then object fall is prevented, but friction increases between the blocker and rollers
Solution Approach 1:
The gap blocker body and legs are designed with flexible characteristics that allow them to conform to the roller surfaces. This flexibility reduces friction by enabling smooth contact and movement with the rotating rollers, while still maintaining the blocking function to prevent object fall through the gap.
4Stability of the object's composition
If multiple legs are used to maintain blocker position, then stability is improved, but device complexity increases
Solution Approach 1:
The blocker is divided into a body and multiple legs, with each leg serving a specific function in maintaining position. This segmentation provides stability through multiple contact points with the rollers while keeping each individual component simple in design. The legs can be independently positioned to contact the rollers at optimal locations, enhancing stability without requiring a complex overall structure.
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
The gap blocker system effectively prevents objects from falling through or becoming lodged between rollers, reduces friction, and minimizes worker safety risks by blocking pinch points, enhancing conveyor operation and safety.
Implementation Method 1
The body has a plurality of resilient, laterally spaced upstream legs with upstream distal end portions and a plurality of resilient, laterally spaced downstream legs with downstream distal end portions
Implementation Method 2
The body has upstream and downstream contact portions configured to form sliding contact with the rollers
Data Source
AI summary
In one aspect, a gap blocker having a body configured to be supported in a gap of a roller conveyor by upstream and downstream rollers. The body has an upper blocking portion with upper contact portions for slidingly contacting the upstream and downstream rollers above a narrowest portion of the gap. The body further includes a plurality of laterally spaced upstream leg portions connected to the upper blocking portion and a plurality of laterally spaced downstream leg portions connected to the upper blocking portion longitudinally spaced from the upstream leg portions. The upstream leg portions have upstream distal end portions to be positioned below the narrowest portion of the gap for keeping the body in the gap. The downstream leg portions likewise have downstream end portions to be positioned below the narrowest portion of the gap for keeping the body in the gap.