Tapered Assist Roller for Case Pivoting on Roller Conveyor
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Solution Overview
Problem
Powered roller conveyors struggle to efficiently rotate lightweight cases 90°, resulting in improper orientation for downstream handling due to insufficient pivoting.
Innovation Solution
A powered roller conveyor with a turning wheel obstruction and an assist roller positioned downstream of the pivot axis, where the assist roller has a higher tangential speed and larger diameter on one side to facilitate complete pivoting of cases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a turning wheel obstruction is used to pivot cases about a vertical axis, then cases can be rotated 90° for downstream handling, but lightweight cases fail to complete the full pivot and remain improperly oriented
Solution Approach 1:
The assist roller is positioned at a specific location downstream of the pivot axis and provides localized rotational assistance only where needed. The roller has a larger diameter and higher tangential speed at the side opposite the pivot axis, creating a localized force that helps lightweight cases complete their pivot without affecting heavier cases that can pivot independently.
Solution Approach 2:
The assist roller has variable parameters along its length - a larger diameter at one end compared to the other. This creates different tangential speeds at different positions, with the higher speed at the side opposite the pivot axis providing the necessary assistance for lightweight cases to complete their rotation.
2Reliability
If all rollers rotate at the same speed, then the conveyor system is simple to control, but lightweight cases cannot gain sufficient rotational momentum to complete their pivot
Solution Approach 1:
Instead of varying the speed of all rollers, only one specific roller (the assist roller) is positioned to provide localized rotational assistance. This roller has a larger diameter at one end, creating higher tangential speed only where needed to assist lightweight cases, while maintaining simple control of the overall conveyor system.
3Speed
If the assist roller has a larger diameter at the side opposite the pivot axis, then it provides higher tangential speed to assist pivoting, but the roller geometry becomes more complex to manufacture
Solution Approach 1:
The assist roller is designed with a gradual diameter change along its length, creating a tapered geometry. This allows the roller to provide higher tangential speed at the side opposite the pivot axis while maintaining a manufacturable form. The tapered shape can be produced using standard machining or forming processes.
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 solution ensures complete 90° rotation of lightweight cases by increasing tangential speed and reducing drag, ensuring proper orientation and handling.
Implementation Method 1
Cases in contact with the obstruction pivot about the pivot axis toward the second side as the supporting rollers rotate. At least one of the rollers is an assist roller disposed downstream of the pivot axis. The assist roller rotates at a higher tangential speed at the second side of the conveyor than at the first side of the conveyor to assist in the pivoting of the cases about the pivot axis.
Implementation Method 2
The assist roller is tapered with a larger diameter at the second side of the conveyor than at the first side to help pivot the cases about the pivot axis
Data Source
AI summary
A case turner comprising a powered roller conveyor with a bump turn and a tapered roller just downstream of the bump turn to assist in turning cases completely 90°. The larger diameter of the tapered roller is on the opposite side of the conveyor from the bump turn.