Soft-Landing Conveyor Rollers With a Belt Cushioning Zone
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conveyor systems often cause damage to items due to the direct impact and transfer of kinetic energy during the conveyance process, lacking effective cushioning mechanisms.
Innovation Solution
A conveyor system design featuring rollers with varying diameters, where the middle portion has a smaller diameter than the end portions, creating a cushioning zone that allows the conveyor belt to deflect and dissipate energy upon impact, combined with a flexible belt material and a control system to manage tension and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional conveyor systems with uniform rollers are used, then the structure is simple and easy to manufacture, but items suffer damage due to direct impact and kinetic energy transfer
Solution Approach 1:
The roller is designed with non-uniform diameter along its length, creating different zones: end portions with larger diameter for structural support and belt contact, and a middle portion with smaller diameter forming a cushioning zone. This local variation in geometry allows the belt to deflect into the cushioning zone, absorbing impact energy and reducing damage to items while maintaining overall structural simplicity
Solution Approach 2:
The varying diameter of the roller creates a pre-formed cushioning zone between the conveyor belt and the roller surface. When an item is placed on the belt, the belt can immediately deflect into this pre-prepared cushioning zone, dissipating kinetic energy before it reaches the item, thereby providing beforehand cushioning protection
2Loss of energy
If the conveyor belt is made flexible to allow deflection, then energy dissipation improves, but belt tension control becomes more difficult
Solution Approach 1:
The roller diameter parameter is varied along its length to create the cushioning zone geometry. This geometric parameter change enables the belt to deflect and dissipate energy through controlled deformation into the cushioning zone, achieving energy dissipation through the belt's inherent flexibility without requiring additional active tension control mechanisms
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 system reduces the force transmitted to items by absorbing kinetic energy, minimizing damage and ensuring safe transportation through controlled deformation and energy dissipation.
Implementation Method 1
allowing the conveyor belt to deflect into the cushioning zone to dissipate at least a portion of energy transferred to the conveyor belt by placing the item onto the conveyor belt
Data Source
AI summary
The present technology is generally directed to a conveyor system and a method of using thereof. In various embodiments, the conveyor system includes: a conveyor belt; a frame; a plurality of rollers supported by the frame and configured to support the conveyor belt, wherein each of the plurality of rollers has two end portions and a middle portion between the two end portions along a length direction of the roller, the roller is supported by the frame at the two end portions, and the middle portion has a smaller diameter than the two end portions; a drive system configured to move the conveyor belt; and a control system configured to control the drive system.