Roller Energy Chain Side-Part Structure for Long-Travel Stability
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Solution Overview
Problem
Existing energy chains for long travels face challenges in achieving robustness, smooth running, and ease of production, while also requiring complex designs with multiple side parts and limited roller diameters, which affect maintenance and operational efficiency.
Innovation Solution
The energy chain design incorporates fork-like and plate-like side parts alternating in strands, allowing for reduced part numbers and improved lateral stability, enabling large roller diameters and simplified installation, with features like guide grooves and extension stop surfaces for enhanced force flow and stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple different side parts (at least six) are used in the energy chain design, then the structural stability and rolling performance are improved, but the manufacturing complexity and production costs increase
Solution Approach 1:
The side part is segmented into modular components: a basic side part design that can be repeatedly used, with optional additions (fork-like structures, guide grooves, extension stop surfaces) only where needed. This allows the energy chain to maintain structural stability through consistent modular units while reducing the total number of different part types required for production.
Solution Approach 2:
The basic side part design is made universal to serve multiple positions in the energy chain structure. By designing a core side part that can function in various locations and combining it with selective additions only where specific functions are needed (such as guide grooves for stability or extension stop surfaces for force distribution), the patent reduces manufacturing complexity while maintaining structural integrity throughout the entire energy chain.
2Device complexity
If smaller roller diameters are used in the energy chain, then the structural complexity is reduced, but the running smoothness and quiet operation deteriorate
Solution Approach 1:
Instead of uniformly reducing roller diameter throughout the energy chain, the patent applies larger roller diameters specifically in critical rolling contact zones where smooth operation is essential. The roller mounting structure is designed with local variations in roller size based on functional requirements, allowing quiet and smooth running in key areas while maintaining overall structural simplicity elsewhere in the energy chain design.
3Length of moving object
If the energy chain is designed for long travels (over 100 m), then the operational capability is improved, but the wear and maintenance requirements increase
Solution Approach 1:
The energy chain incorporates preliminary protective measures against wear before operation begins. Extension stop surfaces are pre-positioned to distribute forces evenly from the start, preventing stress concentration that would lead to premature wear. The modular side part design allows for standardized, pre-tested components with optimized material properties and surface treatments, ensuring consistent wear resistance across the entire 100+ meter travel distance.
Solution Approach 2:
The energy chain design includes self-monitoring and self-adjusting features that reduce maintenance requirements for long travels. The modular construction allows sections to be independently inspected and replaced if needed, while the distributed force flow through extension stop surfaces prevents catastrophic failures and enables gradual, predictable wear patterns that can be monitored and managed over extended operational periods.
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 achieves high stability, reduced production costs, and improved running smoothness with large roller diameters, while simplifying maintenance and allowing longer travels with reduced wear and increased lifespan.
Implementation Method 1
the energy chain is movable such that it forms a type of loop, with an upper run, a lower run and a deflection region connecting the two runs. It is typical in the case of long travels that the upper run is movable resting on the lower run, either in a rolling manner (roller chain)
Data Source
AI summary
Energy chains for guiding lines, such as cables, hoses or the like. In roller chains, rollers are provided on at least some chain links for moving the energy chain in a rolling manner, in particular on chain links of the opposite run, the rotational axis of one roller in each case coinciding with the common pivot axis of a pair of side parts of the chain links. Each of the two strands consists of alternatingly successive first and second side parts, wherein the first side parts are forked with two fork regions which oppose each other in the longitudinal direction and each have a pair of laterally spaced side walls with a plate receptacle therebetween, and wherein the second side parts are plate-like with two plate regions which oppose each other in the longitudinal direction and each engage in a plate receptacle of an adjacent first side part.