Segmented Supporting Roller for Chain Conveyor Maintenance
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Solution Overview
Problem
Supporting rollers on chain conveyers, particularly in the food and bottling industries, tend to block due to dirt and debris, leading to reduced functionality and increased maintenance costs due to complex and expensive fabrication processes.
Innovation Solution
A supporting roller design comprising a rigid first part and a high-friction second part, where the parts can be easily engaged and disengaged to surround a shaft, allowing for quick replacement and effective dirt removal, with features like projections, recesses, and a helical groove to facilitate rotation and cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a supporting roller is made with a rigid part and a high-friction layer mounted on it, then high friction between the chain and roller is achieved, but the fabrication becomes difficult and expensive
Solution Approach 1:
The supporting roller is divided into two separate parts: a rigid roller body and a high-friction layer. These parts can be manufactured independently and then assembled together, simplifying the manufacturing process while maintaining the functional benefits of both materials.
Solution Approach 2:
The roller combines two different materials with complementary properties: a rigid material for structural support and a high-friction material for chain engagement. This composite structure allows each material to be optimized for its specific function while being manufactured separately.
2Stability of the object's composition
If a supporting roller is made as a single complex structure, then it provides structural integrity, but it cannot be easily replaced without dismounting the shaft
Solution Approach 1:
The roller is segmented into multiple parts that can be assembled and disassembled independently. The rigid roller body and high-friction layer can be separated and reassembled without affecting the shaft, enabling quick maintenance and replacement.
Solution Approach 2:
The roller design allows for dynamic assembly and disassembly of its components. The parts can be quickly connected and disconnected from each other, providing maintenance flexibility while maintaining structural integrity during operation.
3Reliability
If the second roller part is made substantially larger than the first roller part, then the high-friction material provides better chain engagement, but the overall roller size increases
Solution Approach 1:
The high-friction layer is applied specifically where it is needed for chain engagement, rather than uniformly across the entire roller. This localized application provides the necessary grip while minimizing the overall size increase of the roller assembly.
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 enhances the longevity of conveyor chains by reducing wear and enabling frequent roller exchange without dismounting the shaft, improving the operational efficiency and reducing maintenance costs.
Implementation Method 1
The second roller part is of a material with high friction, such as a rubber material... This means that the rigid part is engaged to the material made of high friction... In fact, the second roller part may be substantially larger than the first roller part
Data Source
Figure 1
Figure 2a~2c
Figure 2d~2f
AI summary
The invention refers to a supporting roller with a first roller part made of a rigid material and a second roller part made of a material with a high friction such as a rubber material, wherein the first roller part is engaged to the second roller part. Furthermore, the invention refers to a supporting roller with at least a first and a second part that can be engaged with each other such that the first and second part form a bore through which a shaft or rod can be passed such that the at least first and second part completely surround the cross section of the rod or shaft when the at least first and second part are engaged, and when the at least first and second part are not engaged with each other each part can be moved away from the shaft in a radial direction of the shaft without having to pass the ends of the shaft.