Split Clamping Collars for Roller Shaft Static Sealing
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Solution Overview
Problem
Existing machinery roller systems face challenges in maintaining robust seals and preventing lubricant leakage under harsh conditions, such as heavy loads and abrasive materials, which can lead to premature wear and fluid loss.
Innovation Solution
The implementation of clamping collars with splitlines and fasteners to form static seals around the roller shaft ends, combined with dynamic seals between the collars and the roller body, using metal face seals and pins to secure the collars' axial location, creating a robust metal-to-metal sealing mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional roller assemblies are used in harsh conditions, then the structure is simple, but lubricant leakage occurs and seal reliability deteriorates under heavy loads and abrasive materials
Solution Approach 1:
The collar is divided into two separate sections (first collar section and second collar section) that can be assembled around the roller shaft ends. This segmentation allows the sealing surfaces to be precisely fitted to the shaft while enabling easier installation and maintenance, resolving the contradiction between seal reliability and structural complexity
Solution Approach 2:
Sealing elements (such as O-rings or seals) are introduced as intermediary components between the collar sections and the roller shaft. These sealing elements create reliable lubricant containment without requiring complex integrated sealing structures, thus improving seal reliability while maintaining reasonable device complexity
2Loss of substance
If robust sealing mechanisms are implemented, then lubricant leakage is inhibited, but the device complexity increases with additional collars and fasteners
Solution Approach 1:
The collar sections are designed with pre-configured sealing surfaces and mounting features that enable reliable sealing to be achieved during assembly. The sealing elements are pre-installed or easily positioned during the assembly process, ensuring lubricant containment is established before the roller assembly enters service, thus preventing lubricant loss without requiring complex additional components
Solution Approach 2:
The first and second collar sections are positioned to nest together around the roller shaft ends, with sealing elements positioned between them. This nested configuration creates effective sealing with minimal additional space and components, reducing lubricant loss while avoiding excessive device complexity
3Reliability
If clamping collars with fasteners are used, then static seals are formed around roller shaft ends, but the manufacturing complexity increases
Solution Approach 1:
The collar is segmented into two sections that can be manufactured separately using standard machining processes, then assembled around the roller shaft ends. This segmentation allows each section to be manufactured with simpler tooling and processes while still forming reliable static seals through precision-machined sealing surfaces and fastener connections
Solution Approach 2:
The collar sections are designed as universal components that can be applied to various roller shaft configurations. The fastening and sealing features are standardized to work with different shaft sizes and applications, reducing manufacturing complexity by using common design elements across multiple applications
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 solution effectively inhibits lubricant leakage and maintains a robust seal under various loads, extending the service life of machinery roller systems by ensuring reliable fluid containment and reducing wear.
Implementation Method 1
a first fastener clamping the lower and upper collar sections to the first roller shaft end to form a first static seal
Implementation Method 2
a first dynamic seal held in axial compression between the first clamping collar and the roller body
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A machine system (20) includes a roller frame (22) and a roller assembly (30) mounted to the roller frame (22). The roller assembly (30) includes first and second clamping collars (50) positioned upon a roller shaft (32) and each including a lower (52,53) and an upper collar section (54,55). Fasteners (56,60) clamp the lower (52,53) and upper collar sections (54,55) to the roller shaft (32) to form static seals (58,60). The clamping collars (48,50) may be formed with splitlines (72,73) to enable the clamping collars (48,50) to deform so as to simulate interference fits with the roller shaft (32).