Variable Height Rollers for Low Backline Pressure Accumulation
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Solution Overview
Problem
Modular conveyor belts face challenges in accumulating products without backline pressure and damaging high-friction products, with existing solutions either requiring large rollers or complex assembly processes.
Innovation Solution
A modular conveying assembly with actively driven rollers supported above the conveyor module body, utilizing a clutch system to rotate the rollers and a positive stop mechanism to control product positioning, allowing for accumulation without product-to-product contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If rollers are rotatably mounted directly on the hinge pin connecting modules together, then backline pressure is reduced during product accumulation, but the required roller diameter becomes large and extends both above and below the module
Solution Approach 1:
A roller bearing assembly is introduced as an intermediary component between the hinge pin and the roller. The assembly includes a bearing housing that mounts to the module body, with the roller rotatably mounted within the housing. This intermediary structure allows the roller to be positioned at an optimal height above the module top surface without requiring the roller to extend below the module, thereby reducing the effective roller diameter while maintaining low backline pressure during accumulation.
2Object-affected harmful factors
If rollers are supported by roller cradles between modules, then backline pressure is reduced, but the assembly process becomes difficult requiring insertion of rollers into cradles and securing axles through holes
Solution Approach 1:
The bearing housing and roller support functions are merged into a single integrated component that mounts directly to the module body. The roller is pre-mounted within the housing as an assembly unit, eliminating the need for separate cradle components and axle insertion steps. This unified structure simplifies manufacturing and assembly while maintaining the roller support functionality needed to reduce backline pressure during product accumulation.
3Object-affected harmful factors
If a large diameter roller is used to engage objects being conveyed, then backline pressure is reduced during accumulation, but the roller extends both above and below the module when that configuration is not always desired
Solution Approach 1:
The roller bearing assembly is designed with adjustable mounting features that allow the roller position to be dynamically adjusted relative to the module top surface. The bearing housing can be positioned at different heights or orientations depending on the specific application requirements, enabling the system to adapt to different product sizes and conveyance needs while maintaining optimal roller engagement and low backline pressure during accumulation.
Data Source
AI summary
A modular conveying assembly that includes a plurality of roller bodies, a driving member, a positive stop body, and a positive stop actuator. Each roller body includes a top surface, a driven axle mounted to the roller body for conveyance therewith, a roller fixed to the driven axle, and a driven surface fixed to the driven axle. The rollers define a support plane. The driving member selectively engages the driven surfaces to affect rotation of the driven axle. The positive stop body is coupled to the plurality of roller bodies and includes a positive stop that is movable relative to the positive stop body between a first position and a second position. The positive stop extends above the support plane in the second position. The positive stop actuator selectively engages the positive stop to move the positive stop between the first position and the second position.