Extended life roller grill
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Solution Overview
Problem
Existing roller grill drive assemblies are complex, prone to premature wear, and require frequent maintenance due to high component wear and misalignment, leading to reduced reliability and shorter lifespan, with non-replaceable bearing journals exacerbating issues.
Innovation Solution
The introduction of replaceable bearing journals with wider wear surfaces and a simplified drive assembly that evenly distributes force across all rollers, allowing for easy assembly, disassembly, and maintenance, along with self-lubricated bearing surfaces and a method for easy cleaning of burnt-on food buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chain/sprocket drive assemblies are used, then the roller grill can rotate the food products, but the drive components wear prematurely and require frequent maintenance
Solution Approach 1:
The patent replaces the chain/sprocket mechanical drive system with a direct drive mechanism where the motor shaft directly rotates the roller. This eliminates intermediate mechanical components (chains, sprockets, gears, belts) that are prone to wear, contamination by food particles, and require precision adjustments. The direct drive approach fundamentally substitutes a complex mechanical transmission system with a simple direct connection, resolving the reliability and service life issues.
2Power
If worm gear and cog belt drives are used, then the drive mechanism can transmit power, but the assemblies become more complex and require precision adjustments
Solution Approach 1:
The patent extracts and removes the entire worm gear and cog belt transmission subsystem from the roller grill design. By taking out these complex intermediate power transmission components, the design achieves direct power transmission from the motor to the roller. This extraction eliminates the need for precision adjustments, reduces the number of parts, and simplifies the overall assembly while maintaining adequate power transmission capability for the application.
3Stability of the object's composition
If bearing journals are made as part of the housing, then the structure is integrated, but the journals cannot be replaced when worn
Solution Approach 1:
The patent segments the bearing journal from the housing structure, creating a separate replaceable component. The bearing journal is designed as an independent element that can be removed and replaced without replacing the entire housing. This segmentation maintains the structural integrity of the housing while enabling easy replacement of worn bearing journals, directly addressing the repairability issue.
4Reliability
If chain tensioners are added to accommodate wear, then the drive can maintain tension, but the tensioners add to journal wear and premature bearing failure
Solution Approach 1:
The patent eliminates the chain tensioner mechanism by removing the chain drive system entirely. With direct drive, there is no chain requiring tension maintenance, and consequently no tensioner components that would generate additional wear on journals and bearings. The harmful factor of additional wear is eliminated by substituting the entire mechanical tensioning subsystem with a direct connection approach.
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 solution extends the life expectancy of roller grill components, reduces maintenance costs and complexity, and allows for longer operational life beyond 10 years by simplifying maintenance and reducing wear on critical parts.
Implementation Method 1
Rotating food on heated tubes or rods merchandises the food product for sale
Implementation Method 2
self-lubricated bearing surfaces and a method for easy cleaning of burnt-on food buildup
Data Source
AI summary
An extended life roller grills for re-thermalizing and merchandising food product with easily replaceable bearing assemblies, drive assembly and roller tubes. The grill is comprised of rotation of a plurality of heated internally tubes, a drive assembly that transfers rotational motion to the roller tubes from a cam or chain or gear system or cog belt attached to a motor providing rotational motion and force to the roller tubes. Roller grill chain drive or gear drives, or cog belt or cam drives that utilize replaceable bearing assemblies for extending the service life the roller grill. A cam drive assembly substantially increases the reliability, ease of assembly and disassembly, serviceability, and maintenance of the roller grill. Cam drive provides for easy removal, servicing and replacement of roller tubes not available on other drive systems for roller grills. Replaceable bearing journals to extend the life span of chain, gear, cam or belt drive grills.