Slip Roller Conveyor Modular Assembly Design
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Solution Overview
Problem
Conveyor systems are complex and difficult to disassemble for repair or replacement, with existing designs relying on tested but cumbersome fastening and assembly elements, necessitating a simplification of parts and reduction in complexity while imparting multiple functions.
Innovation Solution
The design features a conveyor with laterally spaced side walls and driven roller assemblies, including a center shaft, rotatable pulley, and a drive system with an endless positive drive belt, which allows for efficient and reliable movement of articles along a pathway with adjustable width and reduced part complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fastening and assembly elements are used in conveyor systems, then the conveyor structure is stable and reliable, but the system becomes complex and difficult to disassemble for repair or replacement
Solution Approach 1:
The conveyor system is divided into modular roller assemblies, each comprising a roller, shaft, and bearing that can be independently removed and replaced. This segmentation allows maintenance without disassembling the entire conveyor system, reducing assembly complexity while maintaining structural reliability through standardized modular connections.
Solution Approach 2:
The shaft serves multiple functions: it supports the roller, provides mounting points for bearings, and acts as a structural element connecting to the conveyor frame. This multi-functionality reduces the number of separate components needed, simplifying the overall assembly while maintaining structural integrity.
2Reliability
If conventional roller assemblies with multiple components are used, then the conveyor is reliable, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The roller, shaft, and bearing are combined into a single integrated roller assembly unit that functions as one replaceable component. This merging reduces the number of separate manufacturing processes and assembly steps required, while the internal bearing ensures reliable rotation and support.
Solution Approach 2:
The bearing is nested within the roller assembly, with the roller mounted on the shaft and the bearing positioned between the roller and shaft. This nested configuration allows all components to be manufactured separately but assembled into a compact, reliable unit that simplifies overall manufacturing and maintenance.
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
This configuration enables efficient article movement with reduced maintenance complexity, lower costs due to minimal machining requirements, and the ability to integrate additional functions like docking stations without altering the conveyor structure, enhancing operational efficiency and flexibility.
Implementation Method 1
a drive system including an endless drive belt engaged with said driven pulleys to effect rotation thereof
Data Source
AI summary
In some embodiments, a conveyor may include one or more of the following features: (a) a plurality of driven roller assemblies mounted on said side walls in spaced relationship and at uniform height along the lengthwise direction of said pathway, each said driven roller assembly may include one or more of the following features: i) a center shaft mounted in the side wall so said center shaft is fixed against rotation and projects, perpendicularly inward from the inside surface of the side wall, ii) a driven pulley having an outer flange, an inner axial bore of a size permitting said driven pulley to slide axially over the center shaft, and iii) a roller carried on said driven pulley for rotation therewith to move articles resting on said roller down said pathway, said roller having a recess for engaging a catch on the driven pulley to hold the roller securely.