Variable-Height Ridges for Positive-Drive Spiral Conveyor Belt Engagement
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Solution Overview
Problem
Existing spiral conveyors face issues with high belt tension, frictional wear, and inefficient power usage due to overdrive systems, and challenges in clean engagement and disengagement of the conveyor belt with the drive structure.
Innovation Solution
A spiral conveyor system with a rotatable drive tower featuring parallel ridges that vary in height along its length, engaging the conveyor belt's inside edge to drive it positively without slip, using hinge joints with play to facilitate smooth engagement and disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If overdrive systems are used to reduce maximum belt tension, then belt tension is reduced, but frictional wear increases and power requirements become high
Solution Approach 1:
The drive structure is segmented into multiple drive members (cages or drums) positioned at different locations around the spiral path. Each drive member engages with the belt at a different section, distributing the driving force throughout the entire belt length rather than concentrating it at one location. This segmentation reduces the peak tension required in the belt while minimizing frictional wear through distributed engagement points.
Solution Approach 2:
The patent introduces drive members as intermediary elements between the power source and the conveyor belt. These drive members (cages or drums with drive structure) act as mediators that transfer power to the belt through positive engagement rather than direct frictional contact. This intermediary mechanism reduces both the frictional wear and power losses associated with traditional overdrive systems.
2Loss of energy
If positively driven spiral systems are used to eliminate slip, then frictional losses are reduced, but clean engagement and disengagement of the belt becomes problematic
Solution Approach 1:
The drive members are designed with localized drive structure only at specific engagement zones rather than along the entire circumference. The engagement surfaces are precisely positioned to contact the belt only where needed for power transmission, with tapered or rounded leading edges that facilitate smooth entry. This localized quality approach allows positive engagement where required while maintaining ease of belt loading and disengagement at other locations.
Solution Approach 2:
The drive members are positioned and dimensioned so that the belt naturally engages with the drive structure through its own motion and tension before power transmission begins. The leading edges of the drive members are designed with preliminary geometry (tapered or rounded surfaces) that guides the belt into proper engagement position, eliminating the need for complex alignment procedures during operation.
3Reliability
If drive structure on rotating cage engages belt inside edge, then positive engagement is achieved, but belt tension requirements increase
Solution Approach 1:
The drive structure is divided into multiple separate drive members positioned at different angular locations around the spiral. Each drive member provides positive engagement at a specific section of the belt, distributing the total driving force across multiple engagement points. This segmentation reduces the tension requirement at any single engagement point while maintaining reliable positive engagement throughout the belt length.
Solution Approach 2:
The patent transitions from a single-plane drive mechanism to a three-dimensional arrangement of multiple drive members positioned at different heights and angular locations around the spiral path. This dimensional distribution allows the drive force to be applied through multiple vectors rather than a single high-tension engagement, reducing the peak belt tension while maintaining positive engagement reliability.
Data Source
AI summary
A spiral conveyor for positively driving a conveyor belt along a helical path. The spiral conveyor includes a rotating cylindrical tower with parallel drive members extending from the bottom to the top of the tower on its periphery. Each drive member includes an outwardly protruding ridge that varies in height from the bottom to the top of the tower. The variations in height facilitate the belt's entry onto and exit from the tower and robust, positive driving engagement with the inside edge of the belt along the majority of its path along the tower.