Segmented Track Support Roller With Dry Rolling Interspace
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Solution Overview
Problem
Existing support rollers for vehicle tracks require lubrication, which increases costs, wear, and risk of leaks, while bearing solutions like bearings and sliding bushings are costly and complex.
Innovation Solution
A support roller design with a tubular body that rotates on a shaft composed of multiple cylindrical segments, featuring a complementary internal cavity and interspace for rolling elements, eliminating the need for lubrication and reducing wear by using low-friction rolling elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bearings are arranged between the roller components to support motion transmission, then the functional performance is improved, but the cost of components, assembly and machining increases
Solution Approach 1:
The patent replaces the traditional bearing-based mechanical support system with a polymer material system. The polymer material, positioned between the roller shell and supporting shaft, provides the necessary support and motion transmission functions without requiring complex bearing assemblies, thereby reducing component costs and assembly complexity while maintaining functional performance.
Solution Approach 2:
The patent changes the material parameter from metal bearings to polymer material. This material substitution fundamentally alters the mechanism of motion support, using the viscoelastic properties and friction characteristics of polymers to achieve the same functional outcome as bearings, thus simplifying the overall device structure.
2Device complexity
If sliding bushing is interposed between the shaft and roller to reduce friction, then the cost is reduced, but lubrication is required which introduces leakage risks and thermal limitations
Solution Approach 1:
The patent uses a polymer material that can be easily replaced. The polymer is positioned in a replaceable manner between the roller shell and shaft, allowing for simple maintenance by replacing only the polymer element when worn, rather than replacing entire bearing assemblies or dealing with lubrication system maintenance.
Solution Approach 2:
The patent eliminates the lubrication system entirely by using a dry polymer-based friction reduction mechanism. The polymer material inherently provides low-friction properties without requiring oil or grease, thus eliminating leakage risks and thermal limitations associated with lubrication systems.
3Strength
If welding is used to join roller halves, then the structural strength is improved, but the micrographic and mechanical characteristics of the materials are degraded
Solution Approach 1:
The patent divides the roller into modular components: roller shells, supporting shafts, and replaceable polymer elements. This segmentation allows each component to be manufactured and assembled separately without requiring welding, thus preserving the material characteristics of each component while still achieving strong structural assembly through mechanical connection.
Solution Approach 2:
The patent combines multiple components (roller shells, shafts, polymer elements) into an integrated assembly that functions as a complete roller unit. This merging approach achieves structural strength through the combined action of well-fitted components rather than through welding, avoiding the degradation of material properties.
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 design reduces friction and wear, lowers maintenance costs, and enhances reliability by eliminating the need for lubrication and seals, allowing for faster movement and extended travel times with reduced environmental impact.
Implementation Method 1
an annular interspace for the accommodation of a plurality of rolling elements such as rollers, barrels, balls and the like being formed between said segment having an intermediate diameter of said supporting shaft and said at least one intermediate portion of said tubular body
Data Source
AI summary
A support roller for vehicle tracks, includes a tubular body rotatable on a supporting shaft integral with a chassis; the tubular body has an external surface for accommodating a portion of an internal face of a respective chain. The supporting shaft comprises at least three consecutive cylindrical segments having constant external diameters and increasing progressively from one segment to the next. The tubular body comprises an internal cavity provided with a first portion whose dimensions are complementary to the segment of said shaft that has the largest diameter and an intermediate portion, which in the assembly configuration faces and is proximate to a segment of the shaft having an intermediate diameter; the intermediate portion has a different diameter than the first portion. An annular interspace that accommodates rolling elements is formed between the segment having an intermediate diameter of the supporting shaft and the intermediate portion of the tubular body.