Stationary Accumulating Conveyor Roller Assemblies
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Solution Overview
Problem
Conventional conveyor systems with trolleys attached to belts in the automotive industry face issues such as high side load forces leading to trolley failure, high maintenance costs, and short service life due to the elasticity of the belt, making replacement difficult and costly.
Innovation Solution
A conveyor system with stationary accumulating trolleys using pulleys and roller assemblies with a friction ring mechanism that allows for adjustable frictional engagement, reducing the need for belt attachment and enabling modular assembly for improved reliability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If trolleys are attached to the belt, then the conveyor can move skids, but high side load forces cause trolley failure and belt damage
Solution Approach 1:
The conveyor system is divided into modular sections with independent roller assemblies. Each roller assembly can operate independently, and the system can be configured with different numbers of rollers based on skid load requirements. This segmentation allows the system to handle high side load forces without causing failure of individual components or the entire belt.
Solution Approach 2:
Instead of attaching trolleys to the belt and having the belt move beneath the skids, the invention inverts the approach by using stationary rollers that contact the skids from above. The rollers are mounted on a stationary frame and rotate independently, eliminating the need for belt attachment and reducing side load forces on the belt.
2Productivity
If trolleys are attached to the belt, then skid accumulation is achieved, but replacement of failed trolleys is difficult and costly
Solution Approach 1:
The conveyor system is divided into modular sections with independent roller assemblies. Each roller assembly can be independently replaced without affecting other sections. The standardized modular design allows for easy replacement of failed components using the same procedures for all sections.
Solution Approach 2:
The roller assemblies are pre-assembled as complete modules before installation. This preliminary assembly allows for easy replacement of entire modules rather than individual components, reducing maintenance time and cost. The pre-assembled modules can be quickly swapped out without complex disassembly procedures.
3Productivity
If conventional buffer belt conveyors are used, then skids can be accumulated, but the service life is short due to belt elasticity
Solution Approach 1:
The invention inverts the conventional approach by using stationary rollers mounted on a fixed frame rather than a movable belt. The rollers are positioned to contact the skids from above and rotate independently, eliminating the elasticity problems associated with belt materials. This stationary configuration significantly extends the service life of the conveyor system.
Solution Approach 2:
The invention replaces the elastic belt mechanical system with a stationary roller system. Instead of relying on the elasticity of the belt to accommodate skid accumulation, the system uses rigid stationary rollers that can accommodate skids through independent rotation. This substitution of the mechanical system eliminates belt elasticity issues and extends service life.
4Adaptability or versatility
If the conveyor is designed to handle varying skid loads, then flexibility is improved, but system complexity increases
Solution Approach 1:
The conveyor system is divided into modular sections with independent roller assemblies. Each section can be independently configured and replaced. The standardized modular design allows the system to be adapted to varying skid loads by adding or removing modules rather than redesigning the entire system, reducing complexity despite increased versatility.
Solution Approach 2:
The roller assemblies are designed as universal components that can handle various skid loads and configurations. The same basic roller assembly design can be used across different sections and applications, providing multi-functionality without increasing overall system complexity. The standardized interface allows for easy reconfiguration.
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 maintenance costs, enhances reliability and durability, and allows for flexible configuration to accommodate varying skid loads, extending the service life of the conveyor system while simplifying the replacement of components.
Implementation Method 1
a third ring located radially between and contacting the first and second rings, and alternately transmitting rotary motion from the first ring to the second ring and discontinuing said transmission of rotary motion depending on presence and absence of frictional engagement between the third ring and at least one of the first ring and the second ring
Data Source
AI summary
A conveyor system includes pulleys spaced mutually along a length of the conveyor system; and roller assemblies, each roller assembly aligned with one of the pulleys, including a first ring driveably connected to one of the pulleys, a second ring surrounding the first ring, and a third ring located radially between and contacting the first and second rings, and alternately transmitting rotary motion from the first ring to the second ring and discontinuing said transmission of rotary motion depending on presence and absence of frictional engagement between the third ring and at least one of the first ring and the second ring.