Roller Locking Mechanism With Dual-Spring Lever for Low Switching Force
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Solution Overview
Problem
Existing positive locking devices for rollers, such as those described in WO 2019/053 004 A1 and DE 10 2014 113 460 A1, face challenges in efficiently managing switching forces and accommodating rollers with different wheel diameters, leading to increased operational complexity and component variability.
Innovation Solution
A positive locking device design featuring a first spring acting as a lever arm with a stronger spring force than a second spring, allowing for reduced switching forces and compatibility with rollers of varying diameters through plunger extensions of different lengths, enabling the same components to be used across different wheel sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single spring acts on the rotation-locking engagement part, then the structure is simple, but the switching forces are high and the device cannot accommodate different wheel diameters
Solution Approach 1:
The single spring system is segmented into two springs: a first spring that acts directly on the rotation-locking engagement part and a second spring that acts on the lever part. This segmentation allows the first spring to provide strong locking force while the second spring provides return force, reducing the overall switching force required
Solution Approach 2:
The lever part is introduced as a dynamic element that can pivot between positions. The first spring acts through this lever to amplify its effect on the rotation-locking engagement part, allowing the same component to work effectively with different wheel diameters while maintaining appropriate force levels
2Ease of manufacture
If the plunger part has uniform extensions, then manufacturing is simple, but the device cannot accommodate rollers with different wheel diameters
Solution Approach 1:
The plunger part has extensions with different lengths (first extension longer than second extension) to accommodate different wheel diameters. The longer extension interacts with the lever part for larger wheels, while the shorter extension is positioned for smaller wheels, allowing a single plunger component to serve multiple wheel sizes
Solution Approach 2:
The plunger part is designed with asymmetric extensions that enable it to function with rollers of different wheel diameters. By positioning the plunger at different orientations, the appropriate extension length engages with the lever part, making the same plunger component universal across different roller configurations
3Reliability
If different components are used for different wheel diameters, then each component is optimized, but component variability increases
Solution Approach 1:
The lever part and plunger part are designed as universal components that can work with different wheel diameters. The lever part receives force from the first spring and transmits it to the rotation-locking engagement part, while the plunger part with asymmetric extensions can be positioned to engage the lever at appropriate points for different wheel sizes, eliminating the need for multiple specialized components
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 design reduces switching forces and simplifies manufacturing by allowing the same components to be used for rollers with different wheel diameters, enhancing operational efficiency and reducing component variability.
Implementation Method 1
a first spring acts on the rotation-locking engagement part and is held on a pivotable lever part
Implementation Method 2
a second spring held on the lever part can be tensioned for return movement to the starting position when the rotary locking engagement part is moved into the engagement position
Data Source
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AI summary
The invention relates to a formfitting securing apparatus (14) for a roller (1), comprising an impeller wheel (2), a fork (3) and a rotation-blocking engagement part (43), it being possible for the impeller wheel (2) of the roller (1) to be blocked in rotation with respect to a geometric impeller wheel axis (y) via the formfitting securing apparatus (14), a first spring (58) also acting on the rotation-blocking engagement part (43) in order to move the rotation-blocking engagement part (43) from an initial position into an engagement position. In order to further improve a formfitting securing apparatus of the type in question, the first spring (58) is formed by a lever arm (68) of a lever part (41), a second spring (59) can, with the movement of the rotation-blocking engagement part (43) into the engagement position, be tensioned for the return movement back into the initial position, and the first spring (58) is stronger than the second spring (59). Furthermore, a ram part (33) can be fork-shaped and comprise ram extensions (35, 36) of different lengths, with only one ram extension (35, 36) being arranged to act on the lever part (41).