Self-Cleaning Conveyor Sprocket for Material Buildup Control
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Solution Overview
Problem
Current chain rotating assemblies in agricultural conveyors, such as those in combine harvesters, are prone to material accumulation on sprockets and shafts, leading to increased friction and chain jumping, which reduces durability and efficiency.
Innovation Solution
The design incorporates a sprocket with an annular body, gear teeth, and sloping surfaces that prevent material accumulation, featuring a central plateau portion and sloping surfaces connecting adjacent gear teeth, creating an acute angle that limits or prevents material buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If material accumulates on the sprocket and shaft, then the sprocket can engage the chain, but friction increases and power consumption increases
Solution Approach 1:
The patent extracts the harmful accumulated material from the sprocket surface by designing sloping surfaces that guide material away from the engagement area. The bottom land with sloping surfaces acts as a material removal path, preventing material from remaining on the sprocket where it would cause friction and power loss.
Solution Approach 2:
The patent converts the harmful effect of material accumulation into a beneficial self-cleaning mechanism. The sloping surfaces and acute angles cause accumulated material to naturally slide off the sprocket under gravity and operational forces, transforming the problem of material buildup into a self-cleaning feature that reduces friction and power consumption.
2Ease of operation
If material accumulates under the chain, then the chain can be driven by the sprocket, but chain jumping occurs and durability reduces
Solution Approach 1:
The patent extracts material from beneath the chain by designing the bottom land with sloping surfaces that direct material away from the chain-sprocket engagement zone. This prevents material buildup that would interfere with proper chain engagement and cause jumping.
Solution Approach 2:
The sloping surfaces perform preliminary material removal before material can accumulate under the chain and cause jumping. By proactively guiding material away from critical areas, the design prevents chain jumping and extends chain durability before problems occur.
Data Source
AI summary
A conveyor for a combine harvester includes a chain and a sprocket. The sprocket includes an annular body defining an axis of rotation, two opposing sides, an outer perimeter extending between the two opposing sides, and gear teeth disposed on the outer perimeter. A bottom land extends between valleys of adjacent gear teeth. A single continuous edge is defined between two gear teeth at one of the adjacent sides. The bottom land includes (i) a central plateau portion, (ii) a first sloping surface extending from one edge of the central plateau portion to the single continuous edge at one of the two opposing sides, and (iii) a second sloping surface extending from the opposite edge of the central plateau portion to the single continuous edge at the other of the two opposing sides. The sloping surfaces either limit or prevent the accumulation of material thereon.