Segmented Roller Plate Assembly for Heavy Package Handling
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Solution Overview
Problem
Existing roller mat assemblies in material handling systems are prone to damage from heavy boxes or packages, leading to frequent jams and the need for frequent replacements, causing disruptions in material handling capacity.
Innovation Solution
A roller plate assembly with a base plate featuring a plurality of openings and cross supports, where rollers are mounted on shafts extending through the cross supports, allowing for a package to move across the assembly from one edge to another, and made from durable materials like aluminum and polyoxymethylene, eliminating the need for bearings or bushings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a static roller mat assembly with injection molded plastic base plate is used, then the structure is simple and cost-effective, but the base plate fractures and rollers become damaged when heavy boxes apply significant force
Solution Approach 1:
The base plate is divided into a modular framework structure with multiple independent legs positioned at corners and intermediate locations. Each leg independently supports rollers, allowing localized damage without complete system failure. This segmentation provides structural integrity while maintaining simplicity.
Solution Approach 2:
The invention uses composite construction combining metal framework legs with plastic cross members and roller assemblies. This composite approach provides the strength of metal for load-bearing elements while maintaining the cost-effectiveness and ease of manufacturing of plastic components.
2Ease of operation
If the roller mat assembly is angled at least 8 degrees from horizontal to allow unassisted movement, then gravity facilitates package movement, but heavy packages create significant force that damages the base plate and rollers
Solution Approach 1:
The framework divides the base plate into multiple supported sections with legs at corners and intermediate positions. This segmentation distributes the force from heavy packages across multiple support points, preventing concentrated loads that would damage a solid base plate while maintaining the gravity-assisted angled movement.
Solution Approach 2:
The modular framework structure with multiple independent leg assemblies acts as a cushioning system that absorbs and distributes impact forces from heavy packages before they reach any single structural element, preventing catastrophic failure.
3Ease of manufacture
If rollers are mounted in a solid injection molded base plate, then the assembly is simple to manufacture, but rollers become disabled when the base plate develops cracks and holes
Solution Approach 1:
Instead of mounting rollers in a solid base plate, the invention segments the support structure into independent leg assemblies. Each leg with its rollers can be manufactured separately and assembled into the framework, allowing individual replacement without affecting other rollers and maintaining manufacturing simplicity.
Solution Approach 2:
The roller assemblies are extracted from the base plate structure and mounted on independent legs. This extraction allows rollers to be independently replaced when damaged, without requiring replacement of an entire solid base plate, thereby maintaining ease of manufacture while improving reliability.
4Productivity
If the roller mat assembly becomes damaged and rollers become non-functioning, then jams occur requiring conveyor shutdown and manual clearing, but replacement of the entire assembly causes great disruption to material handling capacity
Solution Approach 1:
The modular framework with independent leg assemblies allows localized replacement of damaged rollers or legs without shutting down the entire conveyor system. This segmentation minimizes productivity loss by enabling maintenance of individual components while other sections continue operating.
Solution Approach 2:
The invention enables dynamic maintenance where individual roller assemblies can be quickly replaced in place, transforming the maintenance process from a static whole-system replacement to a dynamic component-by-component approach that maintains overall system productivity.
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 solution provides a durable and low-maintenance roller plate assembly that reduces the likelihood of damage and jams, minimizing disruptions in material handling operations by allowing heavy packages to move safely and quietly across the assembly.
Implementation Method 1
the roller mat assembly is generally angled at least 8 degrees from the horizontal so that a box or package may move over the rollers unassisted, except for gravity
Data Source
AI summary
A roller plate assembly includes a base plate having a plurality of openings distributed along a length and a width of the base plate. The roller plate assembly includes at least two cross supports coupled to the base plate. The roller plate assembly also includes a roller shaft extending at least partially through the at least two cross supports and a plurality of rollers rotatably mounted to the roller shaft. Each roller is disposed within a corresponding one of the plurality of openings and configured to project at least partly over the upper surface of the base plate. The plurality of rollers are configured to allow a package to move across the plurality of rollers from a first edge of the roller plate assembly to a second edge of the roller plate assembly in the length direction of the base plate.