WO2011127588A1

WO2011127588A1 - Conveyor roller

Info

Publication number: WO2011127588A1
Application number: PCT/CA2011/000427
Authority: WO
Inventors: Stéphane LEBLANC
Original assignee: Groupe Rodillo Inc.
Priority date: 2010-04-15
Filing date: 2011-04-14
Publication date: 2011-10-20

Abstract

The conveyor roller comprises a tubular shell defining a longitudinal axis, a hub and an intermediate ring between the hub and the shell. The hub comprises a shaft member aligned with the longitudinal axis, a bearing support member and a bearing member having an inner race attached to the shaft member and an outer race attached to the bearing support member for allowing relative rotation of the shaft member and the bearing support member. A first releasable attachment member releasably attaches the intermediate ring to the bearing support member and a second releasable attachment member releasably attaches the intermediate ring to the tubular shell.

Description

TTTLE OF THE TNVENTTON: CONVEYOR ROLLER

CROSS-REFERENCE DATA

This application claims the conventional priority of United States Provisional patent application N°61/342,526 filed on April 15, 2010.

FIELD OF THE INVENTION

The present invention relates to conveyor rollers, and more particularly to idle conveyor rollers used to support and carry conveyor belts in light, medium or heavy-duty applications.

BACKGROUND OF THE INVENTION

Idle conveyor rollers are installed on conveyor frame structures to support and carry conveyor belts in many different applications including in the mining industry, the food industry, the pharmaceutical industry, and so on. Articles or bulk material are transferred onto the conveyor belt and supported by the underlying rollers to be conveyed to a desired location. The rollers consequently may be subjected to the load of heavy material, impacts from the articles or bulk material as they are transferred onto the conveyor, or contaminants in the form of dust, dirt, liquids and fluids including corrosive chemical products or other types of products that can be harmful for some materials. It is important that the rollers be sturdy and resistant; but in any event, it is to be anticipated that some rollers will be damaged over the course of a conveyor's lifespan and will need to be replaced.

Prior art rollers do not offer enough resistance to impacts, wear and contaminants and, additionally, require the entire roller to be replaced when part of it is damaged. Often, only the outer shell of the roller may be damaged while the expensive inner components including the shaft and the bearings remain usable. It is a waste to throw away the entire roller.

SUMMARY OF THE INVENTION

A conveyor roller comprising:

• a tubular shell member defining a longitudinal axis;

• a hub comprising: o a shaft member aligned with said longitudinal axis;

o a bearing support member; and

o a bearing member having an inner race attached to said shaft member and an outer race attached to said bearing support member for allowing relative rotation of said shaft member and said bearing support member;

• a first annular intermediate ring;

• a first releasable attachment member releasably attaching said first intermediate ring to said bearing support member; and

• a second releasable attachment member releasably attaching said first intermediate ring to said tubular shell member.

In one embodiment, said first intermediate ring has longitudinal openings made through a peripheral wall member thereof.

In one embodiment, said peripheral wall member of said first intermediate ring comprises:

• an inner wall releasably attached to said bearing support member with said first releasable attachment member;

• an outer wall releasably attached to said tubular shell member with said second releasable attachment member; and

• spokes linking said inner and outer walls in spaced-apart fashion, with said longitudinal openings being defined between said spokes.

In one embodiment, said first attachment member comprises complementary threads provided on said first intermediate ring inner wall and on said bearing support member.

In one embodiment, said second attachment member comprises complementary threads provided on said first intermediate ring outer wall and on an inner wall of said tubular shell member.

In one embodiment, the conveyor roller further comprises:

• a second annular intermediate ring;

• a third releasable attachment releasably attaching said second intermediate ring to said bearing support member; and

• a fourth releasable attachment releasably attaching said second intermediate ring to said tubular shell member. In one embodiment, said first and second intermediate rings have longitudinal openings made therein that are coextensive and that cooperate to allow fluid circulation within said tubular shell member through said longitudinal openings.

In one embodiment, said first and second intermediate rings each comprise:

• a cylindrical inner wall releasably attached to said bearing support member with said first releasable attachment;

• a cylindrical outer wall releasably attached to said tubular shell member with said second releasably attachment; and

In one embodiment, said shaft member comprises two longitudinally spaced apart coaxial stub shafts, said bearing member comprises at least two longitudinally spaced-apart bearings each engaging a corresponding stub shaft, and said bearing support member comprises two longitudinally spaced apart bearing supports each engaging and supporting a corresponding bearing and each engaging and supported by a corresponding one of said first and second intermediate rings.

In one embodiment, said bearing member comprises first and second pairs of bearings, each pair of bearings engaging a corresponding stub shaft.

In one embodiment, each one of said first and second intermediate rings defines opposite first and second ends and comprises a bottom wall at a said first end attached to and forming an intermediate ring enclosure within said cylindrical inner wall wherein corresponding ones of said first and second bearings and of said first and second bearing supports are located; and a ring cover at said second end that releasably engages said inner wall, with a corresponding one of said stub shafts extending through said ring cover.

In one embodiment, each one of said bearing supports defines first and second ends and comprises a hollow bearing support peripheral wall defining a bearing support enclosure wherein a corresponding one of said first and second bearings is located; and first and second bearing support covers located at said bearing support first and second ends that engage said bearing support peripheral wall and close off said bearing support enclosure, with a corresponding one of said stub shafts extending through and sealingly engaging said first bearing support cover.

In one embodiment, said tubular shell member comprises a tubular shell having longitudinally opposite first and second ends and first and second collars each attached to said shell at one end thereof, with said outer wall of said first intermediate ring being releasably attached to said first collar and said outer wall of said second intermediate ring being releasably attached to said second collar.

DESCRIPTION OF THE DRAWINGS

In the annexed drawings :

Figure 1 is a perspective view of a conveyor roller according to a first embodiment;

Figure 2 is an end view of the roller of figure 1;

Figures 3 and 4 are exploded perspective views of the roller of figure 1, taken at different angles;

Figure 5 is a cross-sectional view of the roller of figure 1;

Figures 6 and 7 are respectively a perspective view and a cross-sectional view of a roller according to a second embodiment; and

Figures 8 and 9 are respectively a perspective view and a cross-sectional view of a roller according to a third embodiment.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Figures 1-5 show a conveyor roller 40 for use as an idle roller in a conveyor system to support and carry a conveyor belt for conveying articles or bulk material.

Roller 40 comprises a tubular load-bearing shell member 42 that defines opposite first and second ends 42a, 42b and a longitudinal axis L that extends therebetween. Shell member 42 comprises a tubular shell 44 that defines an outer surface 46 for carrying part of the conveyor belt and receiving the load of the articles being conveyed thereon; and an inner surface 48.

Shell member 42 further comprises a collar 50 attached to shell 44 at one end 42a thereof. Collar 50 is more particularly press-fitted into shell 44 and comprises a tubular main body 52 that engages with its outer surface the inner surface 48 of shell 44. Collar 50 is threaded on its inner surface at 54. An annular flange 56 radially outwardly projects from main body 52 to overlie the annular edge of shell 44 at end 44a. Screws 58 fix flange 56 to the annular edge of shell 44 and cooperate with the press-fit of collar 50 into shell 44 to ensure that collar 50 remains fixedly installed within shell 44 at all times. Other fixing means (not shown) could alternately be used instead of the above-described press-fit and screws 58. Roller 40 comprises a hub 60 comprising a stub shaft 62 that is aligned with longitudinal axis L, a pair of bearings 64, 66 and a bearing support 68. Bearings 64, 66 each have an inner race attached to stub shaft 62 and an outer race attached to bearing support 68 as detailed hereinafter for allowing relative rotation of bearing support 68 with respect to stub shaft 62.

Bearing support 68 defines first and second ends 68a, 68b and comprises a main body 70 having a hollow cylindrical bearing support peripheral wall 72 within which a bearing support enclosure is defined wherein the pair of bearings 64, 66 is located. Bearing support main body peripheral wall 72 has threads on its outer surface and also has threads on its inner surface at second end 68b. Main body 70 further has an annular top wall 76 integrally attached at first end 68a to peripheral wall 72. Stub shaft 62 extends through the central hole 78 of annular top wall 76 and a play exists between stub shaft 62 and top wall 76 to avoid any contact therebetween. Top wall 76 comprises ridges formed on its top surface.

Bearing support 68 also comprises first and second bearing support covers 82, 84 respectively located at bearing support first and second ends 68a, 68b that engage bearing support peripheral wall 72 and close off the bearing support enclosure.

First bearing support cover 82 is annular and defines a central hole 86 through which stub shaft 62extends. Hole 86 is sized to allow first bearing support cover 82 to snugly fit around stub shaft 62 to seal the interface between stub shaft 62 and first bearing support cover 82. First bearing support cover 82 is fixed to and carried by stub shaft 62. First bearing support cover 82 comprises ridges on both its top and bottoms surfaces, with the ridges on the bottom surface cooperating with the ridges on the top surface of the main body top wall 76 to form a first labyrinth seal (see figure 5) that allows rotation of first cover 82 relative to main body top wall 76 while sealing off the bearing support enclosure. Grease or other suitable lubricant sealer may be used in this first labyrinth seal.

Second bearing support cover 84 is threaded on its outer surface to be screwed into bearing support main body peripheral wall 72 at second end 68b, using the inner threads of the latter.

The combination of bearing support main body 70 and bearing support first and second covers 82, 84 forms the bearing support inner enclosure wherein bearings 64, 66 will operate. The bearing support inner enclosure may be flooded with lubricant if desired. In any event, the bearing support inner enclosure is sealed off from outside contaminants. Bearing support main body 70 supports bearings 64, 66 through the instrumentality of a bearing sleeve 88 that is installed within bearing support peripheral wall 72 and more particularly between peripheral wall 72 and the outer races of bearings 64, 66. The outer races of bearings 64, 66 are fixed (e.g. press-fitted) to bearing sleeve 88 and the latter is fixed (e.g. press-fitted) to the bearing support main body peripheral wall 72. Alternately, bearing sleeve 88 could be formed integrally with peripheral wall 72.

Ribs 89 that project downwardly from the bearing support top wall 76 and ribs 91 that project upwardly from the bearing support second cover 84 prevent bearing sleeve 88 from moving longitudinally along stub shaft 62; and also prevent bearings 64, 66 from moving longitudinally along stub shaft 62 beyond the position of ribs 89, 91.

According to the present invention, roller 40 further comprises an annular intermediate ring 90 that links hub 60 to shell member 42 as detailed hereinafter.

Intermediate ring 90 comprises a peripheral wall member 92 formed of an inner wall 94, an outer wall 96 and spokes 98 that integrally link inner and outer walls 94, 96 in spaced-apart fashion. A longitudinal opening 100 is consequently formed between each two consecutive spokes 98. Longitudinal openings 100 extend throughout the entire length of intermediate ring 90. Inner wall 94 is threaded on its inner surface and outer wall 96 is thread on its outer surface.

Intermediate ring 90 is releasably attached to bearing support 68 with a first releasable attachment member in the form of the threads on inner wall 94 operatively engaging the outer threads on the bearing support main body peripheral wall 72. Intermediate ring 90 can consequently be releasably screwed onto bearing support 68.

Intermediate ring 90 is also releasably attached to tubular shell member 42 with a second releasable attachment member in the form of the threads on outer wall 96 operatively engaging the inner threads of collar 50. Intermediate ring 90 can consequently be releasably screwed into tubular shell member 42.

Intermediate ring 90 is provided with a circular bottom wall 101 attached at the bottom edge of its inner wall 94.

An annular intermediate ring cover 102 snaps onto the top edge of the intermediate ring inner wall 94 to form an intermediate ring enclosure within inner wall 94 and over bottom wall 101 wherein bearing support 68 is nested. This further helps prevent contaminants from undesirably entering the bearing support enclosure. A central hole 104 is formed onto intermediate ring cover 102 that allows stub shaft 62 to extend therethrough without cover 102 contacting stub shaft 62 to avoid friction therebetween (i.e. hole 104 is diametrically larger than stub shaft 62). Ridges formed on the bottom surface of cover 102 cooperate with the ridges on the top surface of bearing support first cover 82 to form a second labyrinth seal between intermediate ring cover 102 and bearing support first cover 82 to further seal off the bearing support inner enclosure. Grease or other suitable lubricant/sealer can be used in the second labyrinth seal. Bearing support first cover 82 can consequently rotate between bearing support main body top wall 76 and intermediate ring cover 102.

Ribs 106 are provided atop intermediate ring cover 102 for reinforcement and also aesthetic reasons, with a disposition matching that of spokes 98 to yield the illusion that longer spokes radially extend from the central portion of hub 60 out to shell member 42 (see figure 2).

The result of the above-described roller configuration is one where hub 60 is installed into shell member 42 in releasable fashion by means of the intermediate ring 90.

Another collar, hub and intermediate ring are installed at the second end 42b of shell member 42 and all components thereof are identical and disposed as a mirror image relative to those of the above described collar 50, hub 60 and intermediate ring 90.

In use, the two stub shafts 62 of roller 40 securely and removably mount roller 40 to a conveyor frame structure (not show) for allowing shell member 42 to roll around its longitudinal axis. More particularly, the stub shafts 62 will remain in a fixed position relative to the conveyor frame structure once roller 40 is installed in a manner which is known in the art. Notches 110 are made in the portion of shaft 62 that projects outwardly through the bearing support enclosure and the intermediate ring enclosure to help releasably fix shaft 62 onto the conveyor frame structure. Once thusly installed, roller shell member 42 is free to roll about stub shafts 62. As noted above, shell member 42, intermediate ring 90 and bearing support 68 (except for bearing support first cover 82) all rotate about stub shaft 62 by means of bearings 64, 66. The first labyrinth seal formed between the bearing support first cover 82 and the bearing support main body top wall 76 and the second labyrinth seal formed between the bearing support first cover 82 and the intermediate ring cover 102 cooperate to allow a low-friction seal at the interface between bearing support inner enclosure and the exterior.

Figures 6 and 7 show a second embodiment of a roller 200 according to the present invention and figures 8 and 9 show a third embodiment of a roller 300 according to the present invention. Both rollers 200 and 300 are similar to the roller 40 of the first embodiment shown in figures 1-5, except that the intermediate rings 210 of roller 200 and 310 of roller 300 are of a slightly different configuration. More particularly, the spokes 220 and 320 that link the inner and outer walls 230, 235 and 330, 335 differ from those of the first embodiment in their shape, configuration and disposition. Longitudinal openings 250, 350 still exist between spokes 220, 320. The intermediate ring cover 240, 340 has ribs 245, 345 to match the spokes of each roller 200 and 300. Otherwise, rollers 200 and 300 each have a structure and function as those described for roller 40.

One set of advantages brought about by the roller 40 (and likewise by the rollers 200 and 300) of the present invention relates to the fact that hub 60, intermediate ring 90 and shell member 42 are independently replaceable. Indeed, by unscrewing shell member 42 from intermediate ring 90, shell member 42 may be replaced; by unscrewing hub 60 from intermediate ring 90, hub 60 may be replaced; and by unscrewing both shell member 42 and hub 60 from intermediate ring 90, the latter may be replaced.

Firstly, this allows replacement of some roller components without requiring the replacement of the entire roller. If one of these components is damaged, the others may still be reused. This is particularly advantageous since often the roller shell member 42 may be damaged while the expensive hub 60 will remain usable. This is contrary to prior art devices where the entire roller was disposed of if any portion of it was damaged.

Secondly, a same pair of hubs 60 may be used with shell members 42 of different sizes by changing the intermediate ring 90 and shell member. This allows production of hubs of a single size that are adaptable to shell members of varying sizes simply by using an appropriate intermediate ring.

Use of a removable hub 60 means that hub 60 may be in the form of a cartridge that can be inserted into the roller, providing ease of installation.

Another set of advantages of roller 40 (and likewise of rollers 200 and 300) relates to longitudinal openings 100 that are made in intermediate ring 90.

Firstly, longitudinal openings 100 allow free fluid and air circulation within shell member 42. This significantly helps prevent humidity accumulation within shell member 42, which humidity could, over time, seep into the enclosed housings of the stub shaft assemblies and impede the operation of the bearings; or even attack the structural integrity of roller shell member 42 itself. The longitudinal openings 100 being provided in the intermediate rings at both ends 42a, 42b of shell member 42 are coextensive in the sense that they allow fluid circulation through the entire length of shell member 42.

Secondly, longitudinal openings 100 significantly reduce the overall weight of roller 40. Thirdly, longitudinal openings 100 allow limited resilient deformation of intermediate ring 90 which provides a shock absorption capability to roller 40 between shell member 42 and hub 60. This reduces the risk of the hub components, and in particular the functionally critical stub shaft 62 or bearings 64, 66, being damaged as roller 40 is impacted by external articles or bulk material during use.

Yet another advantage of roller 40 (and likewise of rollers 200 and 300) of the present invention relates to the fact that the intermediate ring 90 offers additional sealing of the bearing support enclosure to avoid contaminants reaching bearings 64, 66. Indeed, intermediate ring inner wall 94, bottom wall 101 and cover 102 cooperate to form an intermediate ring enclosure that helps prevent contaminants from accessing the bearing support enclosure.

The present invention could further be modified beyond what has been described with reference to the annexed drawings, as will be obvious to someone skilled in the art.

For example, the roller can include a shaft member formed of two stub shafts as described above or alternately of a single elongate shaft that extends through the entire shell member. Openings with snug-fit seals (e.g. labyrinth seals) in the bearing support second cover 84 and in the intermediate ring bottom wall 101 could be made to accommodate the passage of this single elongate shaft through shell member 42. The bearings could still be located in fluid- tight enclosures (the bearing support enclosure and the intermediate ring enclosure) to avoid contaminants from reaching them.

The roller may include a bearing member that comprises any suitable number of bearings to allow relative rotation of the shell member with respect to the shaft member. For example, if a single elongate shaft is used, a single or a few bearings could be provided at each extremity of the elongate shaft near the respective ends 42a, 42b of the shell member. Or, alternately, if two stub shafts are used, a single bearing or three or more bearings could be used for each stub shaft instead of the two shown in the drawings.

The roller may include a bearing support member that includes any suitable number of bearing supports for supporting the bearings. For example, a single bearing support could be provided that extends through the entire length of shell member 42, instead of the two bearing supports shown in the drawings. This would be especially relevant if a single elongate shaft was being used. In any event, as noted above, the bearing supports also preferably seal off the bearings from outside contaminants.

The roller may include a single intermediate ring that extends throughout the entire length of the shell member 42 instead of the two shown in the drawings. This is especially relevant if a single bearing support is used that also extends throughout the entire length of shell member 42.

The roller may include an intermediate ring with no longitudinal openings, the intermediate ring then only allowing the independent replacement of the hub and the shell member; and the use of hubs of a single size with shell members of varying sizes.

The longitudinal openings, however, do offer significant advantages as noted above. It is noted that these longitudinal openings in the intermediate ring may be in the form of openings located in-between spokes, but could have other shapes and configurations also such as holes made in an otherwise full intermediate ring annular body. The embodiments shown in figures 1-9 only show some exemplary configurations of longitudinal openings 100, 250, 350.

The roller may include retractable stub shafts that are biased into an operative position similar to the one shown in figures 1-9, but that may be forced against this bias into a retracted position to facilitate or allow installation of the roller onto the conveyor frame structure. Once the roller is in position, the stub shafts could be released to allow them to return to their operative position to operatively engage the conveyor frame structure.

Claims

1. A conveyor roller comprising:

• a tubular shell member defining a longitudinal axis;

• a hub comprising:

o a shaft member aligned with said longitudinal axis;

o a bearing support member; and

• a first annular intermediate ring;

2. A conveyor roller as defined in claim 1, wherein said first intermediate ring has longitudinal openings made through a peripheral wall member thereof.

3. A conveyor roller as defined in claim 2, wherein said peripheral wall member of said first intermediate ring comprises:

4. A conveyor roller as defined in claim 3, wherein said first attachment member comprises complementary threads provided on said first intermediate ring inner wall and on said bearing support member.

5. A conveyor roller as defined in claim 3, wherein said second attachment member comprises complementary threads provided on said first intermediate ring outer wall and on an inner wall of said tubular shell member.

6. A conveyor roller as defined in claim 1, further comprising:

• a second annular intermediate ring;

• a fourth releasable attachment releasably attaching said second intermediate ring to said tubular shell member.

7. A conveyor roller as defined in claim 6, wherein said first and second intermediate rings have longitudinal openings made therein that are coextensive and that cooperate to allow fluid circulation within said tubular shell member through said longitudinal openings.

8. A conveyor roller as defined in claim 7, wherein said first and second intermediate rings each comprise:

9. A conveyor roller as defined in claim 8, wherein said shaft member comprises two longitudinally spaced apart coaxial stub shafts, said bearing member comprises at least two longitudinally spaced-apart bearings each engaging a corresponding stub shaft, and said bearing support member comprises two longitudinally spaced apart bearing supports each engaging and supporting a corresponding bearing and each engaging and supported by a corresponding one of said first and second intermediate rings.

10. A conveyor roller as defined in claim 9, wherein said bearing member comprises first and second pairs of bearings, each pair of bearings engaging a corresponding stub shaft.

11. A conveyor roller as defined in claim 9, wherein each one of said first and second intermediate rings defines opposite first and second ends and comprises a bottom wall at a said first end attached to and forming an intermediate ring enclosure within said cylindrical inner wall wherein corresponding ones of said first and second bearings and of said first and second bearing supports are located; and a ring cover at said second end that releasably engages said inner wall, with a corresponding one of said stub shafts extending through said ring cover.

12. A conveyor roller as defined in claim 11, wherein each one of said bearing supports defines first and second ends and comprises a hollow bearing support peripheral wall defining a bearing support enclosure wherein a corresponding one of said first and second bearings is located; and first and second bearing support covers located at said bearing support first and second ends that engage said bearing support peripheral wall and close off said bearing support enclosure, with a corresponding one of said stub shafts extending through and sealingly engaging said first bearing support cover.

13. A conveyor roller as defined in claim 9, wherein said tubular shell member comprises a tubular shell having longitudinally opposite first and second ends and first and second collars each attached to said shell at one end thereof, with said outer wall of said first intermediate ring being releasably attached to said first collar and said outer wall of said second intermediate ring being releasably attached to said second collar.

14. A conveyor roller as defined in claim 8, wherein said first attachment member comprises complementary threads provided on said first intermediate ring inner wall and on said bearing support member.

15. A conveyor roller as defined in claim 8, wherein said second attachment member comprises complementary threads provided on said first intermediate ring outer wall and on an inner wall of said tubular shell member.