EP4676857A1

EP4676857A1 - Multi-piece roller for a conveyor

Info

Publication number: EP4676857A1
Application number: EP24767717.2A
Authority: EP
Inventors: Jake A. Mohan; Michael Hendrik Degroot; Gerko HULSHOF; Peter HILKHUIJSEN; Paul A. Marsman
Original assignee: Laitram LLC
Current assignee: Laitram LLC
Priority date: 2023-03-06
Filing date: 2024-03-05
Publication date: 2026-01-14
Also published as: AU2024233893A1; CN120693292A; WO2024186794A1; JP2026508177A

Abstract

A multi-piece roller for conveyor belts or chains comprises a first section and a second section that mates with the first section to form a complete roller with a circular rim and a central hub for retaining a shaft. The central hub includes shaped, curving recesses in side walls and locking indents in a peripheral portion. The second section is inserted into spaces in the first section and rotated into an engaged position so that curved protrusions enter the shaped curving recesses and locking bumps engage the locking indents, to form a complete roller.

Description

MULTI-PIECE ROLLER FOR A CONVEYOR

RELATED APPLICATIONS

This application claims priority to US Provisional Patent Application Serial No. 63/450,150, filed March 6, 2023 and entitled "Multi-Piece Roller for a Conveyor" the contents of which are herein incorporated by reference.

BACKGROUND

The invention relates generally to multi-piece rollers that can be assembled on a shaft in an endless conveyor belt system.

Conveyor belts are used in many industries to convey products from a first location to a second location. Conveyor belts generally form an endless belt loop that is trained around drive and idler sprockets or rollers at each end of a conveying path. Articles conveyed atop the conveyor belt are supported along an upper carryway. The conveyor belt returns along a lower returnway. To minimize the maximum sag of the conveyor belt in the returnway, return shoes or rollers are often used. Return rollers typically extend across the width of the conveyor belt at selected positions along the returnway. Rollers may also be used to support a conveyor belt at the infeed end of the endless conveyor belt circuit and — or another location. Mounting rollers, sprockets and other components on a shaft in a conveyor can be difficult and cumbersome. In addition, separate locking components are often required to secure the component in a fixed axial position along the shaft.

SUMMARY

A multi-piece conveyor roller includes a base portion and a cap portion. The cap portion mates with the base portion and rotates into a locked position to form a complete roller with a circular rim and a central hub for retaining a shaft. The central hub includes shaped, curving recesses in side walls. The cap portion is inserted into spaces in the base portion and rotated into an engaged position so that curved protrusions enter the shaped, curving recesses to form a complete roller. According to one aspect, a roller for a conveyor belt comprises a first roller section and a second roller section that mates with the first roller section to form a complete roller. The first roller section comprises a curved peripheral portion defining an outer rim for contacting the conveyor belt. The curved peripheral portion has a space formed by spacedapart, confronting shaped walls. At least one shaped wall includes a locking indent. A hub for receiving a shaft is radially inward of the peripheral portion for receiving a shaft. The hub includes a flat bottom wall, first and second side walls perpendicular to the flat bottom wall and an open end opposite the flat bottom wall. The first and second side walls include shaped recesses. A connecting portion extends from the hub to the curved peripheral portion. The second roller section has a peripheral end inserted in the opening of the curved peripheral portion to complete the peripheral portion. The peripheral end includes a locking bump configured to engage the locking indent. An inner end is inserted in the open end of the hub and includes curved protrusions configured to be received in the shaped recesses of the hub. The second roller section is configured to be inserted in the opening and open end in a first orientation, then rotated about a radial axis to a locked position completing the peripheral portion and hub.

According to another aspect, a roller assembly, comprises a shaft including a plurality of alignment recesses on a peripheral surface and a plurality of multi-piece rollers mounted on the shaft. Each roller comprises a first roller section and a second roller section that mates with the first roller section to form a complete roller. The first roller section has a curved peripheral portion including a space formed by confronting end walls, a locking indent in an end wall of the peripheral portion, a hub radially inward of the peripheral portion for receiving the shaft, and a connecting portion extending from the hub to the curved peripheral portion. The hub includes a flat bottom wall having an alignment bump for engaging an alignment recess, first and second side walls perpendicular to the flat bottom wall and an open end opposite the flat bottom wall. Shaped recesses are formed in the first and second side walls. The second roller section has a peripheral end inserted in the opening of the curved peripheral portion to complete the peripheral portion. The peripheral end includes a locking bump configured to engage the locking indent. The second roller section includes an inner end inserted in the open end of the hub. The inner end includes curved protrusions configured to be received in the shaped recesses of the hub. The second roller section is configured to be inserted in the opening and open end in a first orientation, then rotated about a radial axis to a locked position completing the peripheral portion and hub.

According to another aspect, a method of assembling a multi-piece roller on a shaft comprising the steps of inserting a shaft through an opening in a peripheral portion of a first roller section, seating the shaft in a hub of the first roller section comprising a bottom flat wall and a side walls that are perpendicular to the flat bottom wall, moving a second roller section in a direction parallel to the longitudinal axis of the shaft into the opening until a radial axis of the first roller section aligns with a longitudinal axis of the second roller section and rotating the second roller section about the radial axis until a locking bump in the second roller section engages a locking indent in the peripheral portion of the first roller section and curved recesses in an inner end of the second roller section enter shaped recesses in the side walls of the hub.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a roller assembly for a conveyor including a plurality of multi-piece rollers mounted on a shaft;

FIG. 2 is an exploded view of a roller and shaft of FIG. 1;

FIG. 3 is an isometric view of a cap portion of the roller of FIG. 2;

FIG. 4 is an isometric view of a base portion of the roller of FIG. 2;

FIG. 5 is a cross-sectional front view of the roller of FIG. 2

FIG. 6 is a cross-sectional angled view of the roller of FIG. 2;

FIGS. 7A— 7C show the process of locking the cap portion onto the base portion and shaft of FIG. 2;

FIG. 8 shows a roller assembly of an embodiment with alignment recesses in the body of the shaft according to an embodiment.

DETAILED DESCRIPTION

A multi-piece roller for engaging and supporting a conveyor belt comprises multiple portions that mate together about a shaft. The invention will be described below relative to certain illustrative embodiments, though the invention is not limited to the illustrative embodiments.

Referring to FIG. 1, a conveyor roller assembly 10 comprises a plurality of multipiece rollers 20, 22 mounted on a mounting shaft 12. In one embodiment, the conveyor rollers 20, 22 are returnway rollers, mounted in the returnway of a conveyor for guiding and— or supporting the conveyor belt as it travels from the outfeed, discharge end, back to the infeed of the conveyor. The first roller 20 supports a middle portion of the conveyor belt while a second, edge roller 22, supports an edge portion of the conveyor belt and includes a flange 23 for containing the edge of the conveyor belt. As the conveyor belt moves over the outer rims 160, 161 of the conveyor rollers 20, 22, it may spin the conveyor roller assembly 10. One skilled in the art will recognize that the illustrative conveyor roller assembly may be implemented in any suitable location in a conveyor, such as the infeed or other suitable location where support of a conveyor belt is useful. Alternatively, the rollers 20, 22 may include drive elements to form sprockets for driving a conveyor belt.

Each illustrative multi-piece roller 20, 22 comprises two sections: a first section, shown as a base portion 50, 51 that seats the shaft 12, and a second section, shown as a cap portion 60, 61. The cap portion 60, 61 mates with the base portion 50, 51 to form a complete roller having a circular periphery and capable of supporting a conveyor belt. The illustrative cap portion 60, 61 rotated within an opening of the associated base portion 50, 51 about a radial axis to latch into a mating position. Each section 50, 51, 60, 61 may comprise a single unitary piece or multiple subpieces coupled together.

Referring to FIGS. 2—4, which illustrate the multi-piece flange roller 22 and its components in detail, the illustrative base portion 51 is curved and spans the majority of the circumference of the roller except for a space 40 in the periphery, with the cap portion 61 inserted in the space and completing the circumference when mated to the base portion 51. The middle roller 20 is similar, except for the flange portion 23.

The base portion 51 comprises a collar or central hub 30 defining a central opening 29 for receiving a shaft 12. The illustrative hub 30 and opening 29 are square but can having any suitable size, shape and configuration for receiving a shaft. The hub 30 comprises three perpendicular walls: a bottom wall 31, and two side walls 32, 33. The hub 30 opens to the space 40 in the periphery. The cap portion 61 includes a wall configured to complete and enclose the hub 30, as described below.

The side walls 32, 33 further includes shaped recesses 38 in an upper portion for receiving corresponding protrusions in the cap portion 61. The illustrative shaped recesses have curved side walls, which curve about a radial axis 41 extending through the hub 30 and space 40, and circular segment-shaped top and bottom walls, so that the shaped recesses 38 taper from a central point to the side wall 32 or 33 at each end. The top and bottom walls of the shaped recessed have a flat end interesting the side walls and arc-shaped edges that go into the side walls. The shaped recesses 38 are spaced from the bottom wall 31 by a distance that is slightly larger than the height of a corresponding shaft, so that when a shaft is seated in the hub 30, the shaped recesses 38 are exposed directly above the shaft.

The hub bottom wall 31 includes an alignment bump 39 for locating the roller 22 on an associated shaft. The shaft 12, as described below, includes a corresponding recess for receiving the alignment bump 39.

The hub portion 30 is formed within the base portion 51 and connected to a curved peripheral portion 52 of the base portion 51 by spokes 28, though any suitable means, such as webbing, for connecting the central hub portion 30 to the peripheral portion 52 may be used. The illustrative peripheral portion includes a flange portion 23a, which is omitted for middle rollers 20.

An opening 40 is formed in the peripheral portion 52 to the hub 30 and receives and locks an outer portion of the cap portion 61. The opening 40 aligns with the open end of the hub 30 and provides a passageway from outside the roller 22 to the opening 29 extending along the radial axis 41. The opening 40 is defined by opposing curved, concave surfaces 42, 44 adjacent the outside surface 161 of the rim 52.

Between the curved, concave surfaces 42, 44 and the inner surface of the rim, the opening 40 widens, as shown in FIGS. 5 and 6. In the illustrative embodiment, the top portions of the curved, concave surfaces 42, 44 are vertical (parallel to the radial axis 41) and the bottom portions flare out to form a bell-bottomed shape. The bottom portions further include an indent 46 for receiving a corresponding locking bump on the cap portion 61, as described below. The illustrative cap portion 61 is configured to be inserted into the opening 40 while in a first orientation, then rotate about the radial axis 41 into a locked position, as described below. Prior to inserting the cap portion 61, the shaft 12 is inserted into the central opening 29 via the opening 40 and open end of the hub 30.

The illustrative cap portion 61 includes a peripheral end 62 configured to complete the periphery of the roller 22, an inner end 63 configured to complete the central opening 29 and a connecting portion, shown as a spoke 68, connecting the peripheral end 62 and the inner end 63. The spoke 68 extends along an axis 43 that aligns with the radial axis 41 of the base portion 51 during formation of the complete roller.

The peripheral end 62 includes an outer surface 65 that aligns with the outer surface 161 of the base portion rim 52 to form a complete periphery 161. The peripheral end 62 also includes a flange segment 23b that aligns with the base portion flange segment 23a to form the complete flange 23. The peripheral end 62 has a substantially obround shape, with curved end walls 72, 74 designed to interface the curved, concave surfaces 42, 44 of the base portion opening 40. Shaped, angled locking shelves 76, 78 extend below the curved end walls 72, 74 and flare out to match the flare in the opening 40. The shaped, angled locking shelves 76, 78 include one or more locking bumps 79. As the cap portion 61 rotates about the radial axis 41, each locking bumps 79 wedges into locking engagement with a corresponding indent 46 in the base portion 51.

The illustrative peripheral end 62 further includes a notch 75 in a flat side wall to facilitate gripping and rotating of the cap portion 61 using fingers or a tool that can be inserted therein.

The inner end 63 includes flat side walls 83, 84 and curved locking projections 85, 87 extending from end walls configured to be received in the shaped recesses 38 of the hub 30. The inner end 63 includes a flat inner wall 73 configured to abut and contain the shaft 12.

When assembled, as shown in FIGS. 5 and 6, the shaped recesses 38 receive the curved locking projections, 85, 87, the flat inner wall 73 abuts the top of the shaft 12 and the peripheral end 62 is locked within the space 40. The top surfaces of the locking shelves 76, 78 abut the flaring surfaces of the opening 40, and the locking bump 79 is received in the indent FIGS. 7A— 7C shows the steps involved in assembling a roller 22 of an illustrative embodiment on a shaft 12. After the shaft 12 is inserted in the hub 30 via the opening 40, the cap portion 61 is inserted into the space 40 and open end of the hub 30 at a first orientation, as shown in FIG. 7A. The illustrative first orientation is perpendicular to the assembled orientation. For example, the flat side walls 83, 84 of the cap portion inner end 63 abut the side walls 32, 33 of the hub to allow the inner end to fit in the open end of the hub 30 and the flat inner wall 73 abuts the shaft 12. The bottom wall 73 of the cap portion slides over the shaft 12 in a direction parallel to the longitudinal axis of the shaft 12 until the axes 41, 43 align. Then, the cap portion 61 is rotated about its longitudinal axis 43 and the radial axis 41 within the opening 40, causing the curved locking projections, 85, 87 to enter the shaped recesses 38, the curved end walls 72, 74 to rotate against the curved, concave surfaces 42, 44, and the shaped, angled locking shelves 76, 78 to enter the widened portion of the opening 40. The cap portion 61 continues to rotate until the locking bumps 79 engage locking features 46 within the opening 40 to lock the cap portion 61 to the base portion 51, as shown in FIG. 7C. In this locked position, the flange portions 23a, 23b align with each other to form a complete flange, the outer surfaces 161, 165 align to complete a complete periphery and the inner end 63 of the cap portion 61 encloses and locks to the hub 30 to contain the shaft 12.

Referring to FIG. 8, the shaft 12 may include alignment recesses 18, 19 in a peripheral surface (i.e., the surface that will engage the flat bottom wall 31 of a corresponding hub 30) for receiving alignment bumps 39 in the roller hubs. The location of the alignment recess 18 or 19 may depend on the type of roller being mounted in that region. For example, an inner roller 20 may have an alignment recess 18 that is centered on the shaft, while an edge roller 22 may have an alignment recess that is offset from the center of the shaft to prevent assembly of the rollers in the wrong axial position.

Although the invention has been described in reference to a version of a roller, other versions are possible, and the invention is not limited to the illustrative embodiments.

Claims

What is claimed is:

1. A roller for a conveyor belt comprising: a first roller section having a curved peripheral portion defining an outer rim for contacting the conveyor belt, the curved peripheral portion having a space formed by spaced-apart, confronting shaped walls, at least one shaped wall including a locking indent; a hub for receiving a shaft radially inward of the peripheral portion, the hub including a flat bottom wall, first and second side walls perpendicular to the flat bottom wall and an open end opposite the flat bottom wall, the first and second side walls including shaped recesses; and a connecting portion extending from the hub to the curved peripheral portion; and a second roller section having a peripheral end inserted in the opening of the curved peripheral portion to complete the peripheral portion, the peripheral end including a locking bump configured to engage the locking indent; and an inner end inserted in the open end of the hub, the inner end including curved protrusions configured to be received in the shaped recesses of the hub, wherein the second roller section is configured to be inserted in the opening and open end in a first orientation, then rotated about a radial axis to a locked position completing the peripheral portion and hub.

2. The roller of claim 1, wherein the peripheral end of the second roller section has a substantially obround shape.

3. The roller of claim 2, wherein the peripheral end includes a notch in a flat side wall.

4. The roller of claim 1, wherein confronting end walls of the curved peripheral portion in the first roller section comprise curved concave surfaces and the peripheral end of the second roller section includes curved end walls configured to interface the confronting end walls of the first roller section.

5. The roller of claim 1, wherein the confronting end walls include bottom portions that flare out to form a bell-bottomed shape and the peripheral end of the second roller section includes shaped, angled locking shelves below the curved end walls.

6. The roller of claim 5, wherein the locking bump is formed on a shaped, angled locking shelf.

7. The roller of claim 1, wherein shaped recesses in the hub include top and bottom walls that are circular segment-shaped.

8. The roller of claim 1, wherein the shaped recesses are spaced from the flat bottom wall by a distance that is slightly greater than a height of a shaft received in the hub.

9. The roller of claim 1, wherein the curved peripheral portion of the first roller section includes a flange and the peripheral end of the second roller section includes a flange segment that aligns with the flange.

10. The roller of claim 1, wherein the flat bottom wall of the hub includes an alignment bump for locating the roller on an associated shaft.

11. A roller assembly, comprising: a shaft including a plurality of alignment recesses on a peripheral surface; and a plurality of multi-piece rollers mounted on the shaft, each roller comprising a a first roller section having a curved peripheral portion including a space formed by confronting end walls, a locking indent in an end wall of the peripheral portion, a hub radially inward of the peripheral portion for receiving the shaft, the hub including a flat bottom wall having an alignment bump for engaging an alignment recess, first and second side walls perpendicular to the flat bottom wall and an open end opposite the flat bottom wall, shaped recesses in the first and second side walls and a connecting portion extending from the hub to the curved peripheral portion; and a second roller section having a peripheral end inserted in the opening of the curved peripheral portion to complete the peripheral portion, the peripheral end including a locking bump configured to engage the locking indent and an inner end inserted in the open end of the hub, wherein the inner end includes curved protrusions configured to be received in the shaped recesses of the hub, wherein the second roller section is configured to be inserted in the opening and open end in a first orientation, then rotated about a radial axis to a locked position completing the peripheral portion and hub.

12. The roller assembly of claim 11, wherein a first multi-piece roller includes an alignment bump in a center of the hub and a second multi-piece roller includes an alignment bump that is offset from a center of the hub.

13. The roller assembly of claim 12, wherein the first multi-piece roller includes a flange.

14. The roller of claim 11, wherein shaped recesses in the hub include top and bottom walls that are circular segment-shaped.

15. The roller of claim 11, wherein the confronting end walls include bottom portions that flare out to form a bell-bottomed shape and the peripheral end of the second roller section includes shaped, angled locking shelves below curved end walls.

16. A method of assembling a multi-piece roller on a shaft, comprising the steps of: inserting a shaft through an opening in a peripheral portion of a first roller section; seating the shaft in a hub of the first roller section comprising a bottom flat wall and a side walls that are perpendicular to the flat bottom wall; moving a second roller section in a direction parallel to the longitudinal axis of the shaft into the opening until a radial axis of the first roller section aligns with a longitudinal axis of the second roller section; and rotating the second roller section about the radial axis until a locking bump in the second roller section engages a locking indent in the peripheral portion of the first roller section and curved recesses in an inner end of the second roller section enter shaped recesses in the side walls of the hub.

17. The method of claim 16, wherein the step of seating the hub comprises engaging an alignment bump in the bottom wall of the hub with an alignment recess in the shaft.

18. The method of claim 16, wherein the step of rotating comprises inserting a tool in a notch formed in the second roller section to facilitate gripping and rotating of the second roller section.