Surface-Mounted Conveyor Drive Mechanism Eliminates Sub-Surface Cavity
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Solution Overview
Problem
Current conveyor systems require a sub-surface drive mechanism, which is costly and laborious to install, as they need a large cavity in the manufacturing floor to collect excess chain, leading to potential tangles and design constraints.
Innovation Solution
The system employs a surface-mounted drive mechanism with a calibrated log chain and tow pin assembly, allowing for adjustable speed and cart delays, along with an above-ground drive assembly that uses springs for tensioning, eliminating the need for a sub-surface cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sub-surface drive mechanism is used to collect excess chain, then chain tension is maintained and tangling is prevented, but installation cost and complexity increase significantly
Solution Approach 1:
The invention extracts the chain collection function from the sub-surface cavity and relocates it to an above-ground chain basket assembly. The chain basket is positioned above the drive mechanism, allowing excess chain to be collected and contained without requiring floor cavities. This separates the chain management function from the structural floor modification, dramatically reducing installation complexity while maintaining chain tension control.
Solution Approach 2:
The invention transitions from a vertical subsurface solution (below-floor cavity) to a horizontal above-ground solution (side-mounted chain basket). By positioning the chain basket laterally adjacent to the drive mechanism rather than beneath it, the system uses horizontal space instead of vertical floor depth, eliminating the need for costly floor modifications while achieving the same chain management objective.
2Ease of operation
If a large sub-surface cavity is created to house the drive mechanism, then the drive mechanism can be properly positioned, but floor modification becomes laborious and expensive
Solution Approach 1:
The invention extracts the drive mechanism from its traditional sub-surface location and repositions it above ground level. The drive mechanism is mounted on the side of the conveyor structure rather than being embedded in the floor, eliminating the need for large cavity excavations while maintaining proper drive positioning and operational functionality.
Solution Approach 2:
Instead of placing the drive mechanism below the floor surface as in conventional designs, the invention inverts the arrangement by positioning the drive mechanism above ground level. This reversal of the traditional vertical arrangement eliminates the need for floor cavities while achieving the same mechanical functionality through an alternative spatial configuration.
3Quantity of substance
If the drive mechanism is placed below the drive chain housing, then excess chain can be collected, but the cavity may bind up and become tangled without proper tension
Solution Approach 1:
The invention introduces a chain tensioning device as an intermediary component between the drive mechanism and the chain basket. This device actively maintains chain tension, preventing the excess chain from binding or tangling within the chain basket. The tensioning device acts as a mediator that ensures proper chain management while accommodating the above-ground chain collection arrangement.
Solution Approach 2:
The chain basket assembly is designed to work in conjunction with the tensioning device to automatically manage excess chain. As chain is added or removed from service, the tensioning device self-adjusts to maintain proper tension, and the chain basket automatically contains the appropriate amount of excess chain without requiring manual intervention or sub-surface positioning.
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 reduces installation costs and complexity, allows for versatile conveyor system configurations, and prevents chain tangling by maintaining tension without a sub-surface recess, enhancing operational efficiency and flexibility.
Implementation Method 1
a spring adapted to apply a force between the drive motor and the mount surface to tension the conveyor tow chain
Implementation Method 2
allowing the chain to collect in the cavity allows gravity to act on the excess chain and provide the tension necessary to prevent the excess chain from binding up or tangling
Data Source
AI summary
Systems, methods, and apparatuses relating to improved conveying systems, and in particular to providing locomotion preferably using a surface mounted drive mechanism for driving a drive chain are provided. Generally, the conveying system of the present invention is designed to adapt to most manufacturing needs, for example, from furniture manufacturing and finishing to marine and automotive engines. In one embodiment, the present invention provides a conveying system, comprising: at least one load carrying unit having a tow pin assembly, the tow pin assembly further comprising a tow pin configured to link to and delink from a conveyor tow chain, and the tow pin configured to engage and disengage from the conveyor tow chain; a conveyor track configured to house the conveyor tow chain; and a drive assembly configured to receive the tow chain and to provide locomotion to the conveyor tow chain, and further comprising at least one tensioner for tensioning the conveyor tow chain.