Two-Part Sprocket Wheel for Cleanable Conveyor Axle Engagement
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Solution Overview
Problem
Conventional sprocket wheels in conveyor systems, particularly in the food industry, are difficult to clean thoroughly due to closed or enclosed spaces, which complicates maintaining high hygienic standards and require extensive disassembly for replacement, leading to increased downtime.
Innovation Solution
A two-part sprocket wheel design with engagement ridges and assembly flanges that allow for easy cleaning and replacement without disassembling the entire conveyor structure, featuring a central aperture for a rectangular axle, orthogonal engagement ridges, and circumferential ridges to ensure a secure and clean connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a conventional single-piece sprocket wheel is used, then the structure is simple and secure, but it requires extensive disassembly of the conveyor structure for replacement and has enclosed spaces that are difficult to clean
Solution Approach 1:
The sprocket wheel is divided into two separate periphery elements that can be assembled around the drive axle independently. Each element has engagement ridges that fit into grooves on the axle, allowing the sprocket wheel to be installed without disassembling the conveyor structure. The two elements are connected through assembly flanges with fastening means, creating a functional single-piece sprocket wheel while maintaining ease of replacement.
2Ease of manufacture
If a conventional single-piece sprocket wheel is used, then the structure is simple, but enclosed spaces make thorough cleaning difficult and compromise hygienic standards
Solution Approach 1:
By dividing the sprocket wheel into two periphery elements with a gap between them, the design eliminates enclosed spaces where debris could accumulate. The gap allows cleaning fluids to reach all surfaces, including the engagement ridges and assembly flanges, while the modular construction remains simple to manufacture.
Solution Approach 2:
The assembly flanges and fastening means are positioned on the outer periphery of the sprocket wheel elements, away from the central engagement area with the drive axle. This extraction of the connection mechanism to the periphery creates open access to the central area, eliminating enclosed spaces and enabling thorough cleaning of all surfaces.
3Loss of time
If the sprocket wheel is designed as two separate parts assembled around the axle, then replacement is easier, but the connection mechanism adds complexity and potential enclosed spaces
Solution Approach 1:
The two periphery elements are designed as identical or complementary segments that can be assembled independently around the drive axle. Each element has its own engagement ridges and assembly flanges, allowing for simple, tool-free assembly that minimizes downtime while avoiding complex multi-component connection mechanisms.
Solution Approach 2:
The engagement ridges on the periphery elements automatically engage with the grooves on the drive axle through elastic deformation of the ridges, creating a self-centering and self-locking mechanism. This eliminates the need for complex alignment tools or adjustment mechanisms, reducing both complexity and installation time.
Data Source
AI summary
A two part sprocket wheel engages modular belt modules in a conveyor belt. The sprocket wheel's periphery elements' outer edges form a full circle. On each inner periphery four engagement ridges are provided. When the sprocket wheel is mounted around the axle, only the engagement ridges touch and engage the axle. The sprocket wheel construction between the engagement ridges is removed from the drive axle. It is possible to flush and clean the areas around the drive axle being partly covered by the sprocket wheel in an easy and accessible manner. The engagement ridges have a very limited engagement area in order to contact the drive axle and thereby convey the torque forces from the drive axle to the teeth of the sprocket wheel. The engagement ridges are in very firm engagement with the drive axles, such that no material may remain where the engagement ridges engage the drive axles.