Snub Idler Convex Rollers Conveyor Belt Trough Positioning
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Solution Overview
Problem
Conveyor systems with partial trough transitions experience vertical movement of the conveyor belt, leading to seal degradation and material entrapment, which results in dust leakage and conveyor damage, while full trough transitions are costly due to increased length requirements.
Innovation Solution
The introduction of a snub idler with convexly shaped rollers and a support structure that positions the conveyor belt to conform to a concave trough shape, eliminating upward movement and reducing space requirements, thereby maintaining belt engagement with impact idlers and saddles without excessive tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a partial trough transition is used, then space requirements are reduced, but vertical movement of the conveyor belt occurs causing seal degradation and dust leakage
Solution Approach 1:
A snub idler is introduced as an intermediary component between the tail pulley and the impact load bed. The snub idler has rollers that contact the conveyor belt and force it downward into the trough shape, preventing the belt from rising upward. This mediator component solves the problem by eliminating vertical movement of the belt while allowing the partial trough transition configuration to maintain reduced space requirements.
2Reliability
If a full trough transition is used, then vertical movement of the conveyor belt is eliminated, but conveyor length and cost increase
Solution Approach 1:
The snub idler acts as a mediator that enables the conveyor belt to be forced into the trough shape at an intermediate point, eliminating the need for a full-length trough transition. By using the snub idler to apply downward force on the belt, the system achieves belt position stability without requiring the entire conveyor to be configured as a full trough transition, thus reducing overall length.
Solution Approach 2:
Instead of implementing a full trough transition throughout the entire conveyor length, the invention applies the trough-shaping action partially by using the snub idler at a specific location. This partial action is sufficient to prevent vertical belt movement and eliminate the harmful effects, while avoiding the excessive length and cost associated with a complete full trough transition design.
3Object-affected harmful factors
If flexible seals contact the conveyor belt to prevent dust leakage, then environmental compliance is improved, but seal degradation occurs due to vertical belt movement
Solution Approach 1:
The snub idler serves as a mediator that prevents vertical movement of the conveyor belt, thereby protecting the flexible seals from degradation. By forcing the belt into the trough shape and eliminating upward motion, the snub idler ensures that the seals maintain constant contact with the belt without experiencing the stress and wear that would otherwise occur, extending their service life while maintaining dust prevention effectiveness.
Data Source
AI summary
Disclosed is technology including a snub idler for a conveyor having a plurality of rollers and a frame comprising means to support the plurality of rollers in a convex or similar shape. The means to support the plurality of rollers in a convex shape may include a pair of convex arcuate or similar rails respectively affixed to a side panel of the frame. The present technology also includes a conveyor including a tail pulley, an impact load bed defining a trough and having a concave shape, and one or more snub idlers positioned between the tail pulley and the impact load bed. In this arrangement the snub idler supports a plurality of rollers having a convex or similar shape generally complementary with the concave shape of the impact load bed trough. The disclosed technology also includes a method of positioning and shaping a conveyor belt, including configuring a snub idler having a plurality of roller segments, with each roller segment having a roller, wherein the rollers define a convex or similar shape generally complementary with a concave shape of a trough defined by an impact load bed of a conveyor. This method further includes positioning the snub idler longitudinally between a tail pulley of the conveyor and the impact load bed, and supporting the snub idler with a snub idler support structure such that the roller of at least some of the roller segments of the snub idler is in contact with an upper surface of the conveyor belt and forces the conveyor belt down into the trough.