Roller Conveyor Gap Blocker With Low-Friction Roller Contact
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Solution Overview
Problem
Roller conveyors experience issues with items falling through gaps between rollers, leading to damage of underlying structures and operational disruptions, and existing solutions often increase frictional resistance and wear on the rollers.
Innovation Solution
A gap blocker with a body having an upper blocking portion and leg portions that are shiftable to fit into the gap, minimizing contact with rollers to reduce friction and prevent items from falling through, while maintaining efficient conveyor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gap blocker is installed to prevent items from falling through gaps, then reliability is improved, but frictional resistance increases
Solution Approach 1:
The gap blocker body is divided into multiple contact portions (upper contact portions and lower contact portions) that are spatially segmented to contact different rollers at different locations. This segmentation allows the blocker to prevent items from falling through while minimizing the contact area with each individual roller, thereby reducing frictional resistance.
Solution Approach 2:
The contact portions are designed with specific local geometries and material properties optimized for their function. The contact surfaces are made smooth and curved to match the roller surfaces, creating localized contact points with minimal friction. The body material is selected to have low friction characteristics against the roller material.
2Reliability
If the gap blocker contacts rollers to prevent item passage, then reliability is improved, but wear on rollers increases
Solution Approach 1:
The gap blocker body is designed as a replaceable component with a shorter service life than the rollers. When the blocker shows signs of wear, it can be easily removed and replaced without affecting the rollers, which are more expensive and have longer operational lifespans. This protects the rollers from excessive wear.
Solution Approach 2:
The contact portions of the gap blocker are designed to have homogeneous material composition and surface properties that match or are compatible with the roller material. This ensures uniform contact and distributes wear evenly, preventing localized damage to the rollers.
3Stability of the object's composition
If the gap blocker is designed with extensive contact with rollers, then stability is improved, but frictional resistance increases
Solution Approach 1:
The gap blocker is designed with dynamic characteristics that allow it to adapt to roller position variations and operational conditions. The flexible mounting or resilient elements enable the blocker to maintain stable contact with rollers while accommodating minor misalignments, ensuring stability without requiring excessive contact pressure that would increase friction.
Data Source
AI summary
In one aspect, a gap blocker having a body with an upper blocking portion and leg portions of the body connected to the upper blocking portion at longitudinally spaced apart locations. The leg portions of the body have an initial, undeflected configuration with at least one of the leg portions having a first orientation relative to the upper blocking portion. The leg portions of the body have an operating configuration with the body in a gap between rollers wherein the at least one of the leg portions has the first orientation relative to the upper blocking portion. The upper blocking portion has upper contact portions and the leg portions have lower contact portions for contacting the rollers. The body also has outer surface portions intermediate the upper and lower contact portions configured to be in clearance with the rollers.