Motor Cartridge for a Roller With One-End Shape Coupling

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Solution Overview

Problem

Existing roller conveyors face issues with friction-based gaskets in motorized rollers losing effectiveness over time, leading to reduced motion transmission, increased machine downtime, and economic losses due to frequent motor replacements.

Innovation Solution

A motor cartridge design with a single bearing supporting the stator and rotor, allowing torque transfer through shape coupling at one end, reducing the need for motor extraction and simplifying maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If friction-based gaskets are used to transmit motion from the motor to the roller cylinder, then the motor can be arranged inside the hollow cylinder, but the gaskets lose effectiveness over time leading to reduced motion transmission and increased machine downtime

Engineering Contradiction:

Improvemotor arrangementVSAvoidmotion transmission

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent extracts the gasket component from the motion transmission system and replaces it with a direct mechanical coupling mechanism. The motor is positioned inside the hollow cylinder but connects to the roller through a reliable mechanical interface rather than friction-based gaskets, eliminating the reliability issue while maintaining the compact internal arrangement.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the friction-based mechanical system (gaskets) with a more reliable mechanical coupling system. This substitution eliminates the degradation problem inherent in friction-based transmission and provides consistent motion transmission throughout the operational life of the motor.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If friction-based gaskets are used for motion transmission, then the motor can be integrated into the roller, but frequent motor replacement is required leading to increased machine downtime and economic losses

Engineering Contradiction:

Improvemotor integrationVSAvoidmachine downtime

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The patent extracts the gasket element that causes motor failure and replaces it with a durable mechanical coupling. This allows the motor to remain integrated in the roller without the need for frequent replacements, significantly reducing machine downtime and maintaining continuous operational efficiency.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent implements a design that prevents future motor failures by using a robust mechanical coupling system from the outset. This beforehand cushioning approach eliminates the progressive degradation that would otherwise lead to motor failure and costly downtime.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Device complexity

If gaskets are used to transmit torque from the motor, then the motor can be positioned inside the roller cylinder, but the gaskets undermine transmission effectiveness reducing control of conveyed material

Engineering Contradiction:

Improvemotor positioningVSAvoidmaterial control

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The patent replaces the friction-based gasket system with a direct mechanical coupling that ensures reliable torque transmission. This substitution maintains the motor's integrated positioning while restoring full control over the conveyed material through consistent and predictable motion transmission.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enhances operating reliability and reduces machine downtime by ensuring efficient torque transmission and easy replacement of the motor cartridge, maintaining high operational efficiency.

Implementation Method 1

transmit the drive torque to the roller by friction coupling

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

transmit the drive torque to the roller by friction coupling

Methodology Applied

Scientific EffectShape coupling: Mechanical Fastener

Data Source

PatentUS12454416B2Motor cartridge for roller, roller

Publication Date: 2025.10.28 RULLI RULMECA

AI summary

A roller is provided which has a roller body extending between a first roller end and a second roller end, the roller body defining a motor cartridge seat therein, and a motor cartridge having an elongated cartridge body extending along an axial direction between a first cartridge body end and a second cartridge body end, and a motor unit supported at the first cartridge body end. The motor cartridge is connected to the roller exclusively by the first cartridge body end leaving the cartridge body projecting in a cantilever manner. The motor unit transmits a rotation torque to the roller by shape coupling exclusively through the first cartridge body end.