Abstract:
By housing a driver circuit board in a motorized roller having a built-in electric motor, the troublesome external wiring can be dispensed with, thereby facilitating the mounting of the roller on other apparatus. The heat generating inside the roller from a driver circuit board in the roller is dissipated by a heat releaser, thus protecting the devices from damage and avoiding failure of control.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to a roller driven by its own built-in electric motor. Herein, this type of roller will be called “motorized roller”.  
           [0003]    2. Description Of Related Art  
           [0004]    The motorized rollers are in wide use in conveyors for transporting commodity and products. The motorized roller usually incorporates a speed reducer, and the typical examples are disclosed in Japanese Laid-open Patent Applications Nos. Hei 11-79358, Hei 8-188219, Hei 8-2643, Hei 7-279998, and Hei 6-227630.  
           [0005]    The known motorized rollers use an induction motor. In recent years, in order to meet the general demand for more precise control, it is common that the motorized rollers use brushless motors.  
           [0006]    The main advantages of a brushless motor are the omission of a brush or communicator, the attainment of a constant output for the same conditions, and the operational efficiency.  
           [0007]    On the other hand, the brushless motor has disadvantages that it requires a pole detector which needs lead wires in addition to the power cable, and a complicated motor driver circuit board must be equipped to control a current supplied to the brushless motor, the circuit board being mounted on the body of the motorized roller, and the lead wires from the roller being connected to the circuit board. The external wiring is a troublesome work. An example is disclosed in Japanese Laid-open Patent Application No. Hei 8-91532.  
           [0008]    Therefore, the known motorized roller using a brushless motor is practically disadvantageous in that the consumption of time and toil is involved in electrical connection when the motorized roller is incorporated in machines such as conveyors, and the wiring tends to become twisted in an untidy state. In addition, the repair of the motorized roller consumes time and toil.  
           [0009]    The present invention is directed to solve the problems pointed out above, and has for its object to provide a motorized roller which ensures easy wiring connection and ready installing into other machines such as conveyors.  
           [0010]    Another object of the present invention is to provide a motorized roller capable of releasing heat which otherwise would be likely to build up in the roller body and damage the component parts therein.  
         SUMMARY OF THE INVENTION  
         [0011]    According to one aspect of the present invention, the motorized roller includes a roller body, an electric motor, a speed reducer, and an electronic device accommodated or housed within the roller body to control a current supplied to the motor, wherein the roller body accommodates the electric motor and the speed reducer, and is rotated by the electric motor through the speed reducer.  
           [0012]    According to another aspect of the present invention, the motorized roller includes a roller body, an inner shell, an electric motor, a speed reducer, and an electronic device housed within the inner shell to control a current supplied to the motor, wherein the inner shell accommodates the electric motor and the speed reducer, and the roller body is rotated by the electric motor through the speed reducer.  
           [0013]    According to a further aspect of the present invention, the motorized roller has a roller unit which includes a casing, a fixed shaft protruding from the casing, a driving portion provided within the casing, an electronic device housed within the casing, and a rotating member having a larger diameter than the casing, wherein the driving portion includes an electric motor, the electronic device is adapted to control a current supplied to the motor, and the rotating member is rotatable upon reception of a force from the driving portion. When the casing is inserted in an external roller separately prepared, the fixed shaft protrudes from the external roller and the rotating member engages with an inner surface of the external roller to rotate the external roller.  
           [0014]    Preferably, the motorized roller includes a heat releaser housed within the roller body, wherein the heat releaser directly or indirectly contacts the electronic device so as to allow heat generating in and around the electronic device to dissipate.  
           [0015]    Preferably, the electronic device incorporated in the motorized roller of the present invention is a transistor to control a current supplied to the motor but as a result of the amplification of a current through the transistor, heat generates, and builds up in the roller body. The heat is likely to damage the components, and lead to loss of control. Therefore, the dissipation of heat is essential for smoothly operating the motorized roller.  
           [0016]    It is preferred that thermally conductive grease is applied between the heat releaser and the electronic device to facilitate heat transfer between them.  
           [0017]    The heat releaser and the electronic device may be separated by a suitable electrical insulator, which hereafter will be referred to as “insulator”.  
           [0018]    According to a further aspect of the present invention, an inner shell is provided in the roller body to accommodate the electronic device and a heat releaser, such as through radiation and conduction, which is directly or indirectly kept in contact with the inner shell and the electronic device. The heat releaser housed inside the inner shell together with the electronic device works as a heat radiator for dissipating heat generating in and around the electronic device. In this case, the inner shell also radiates and dissipates heat and works as a part of the heat radiator, whereas the heat releaser works also as a heat conductor. Preferably, the area of the outer surface of the inner shell is larger than that of the heat releaser so as to facilitate heat dissipation. Thus the electronic device and others are protected from being damaged by heat. The inner shell is fixed with respect to the ground or floor; if it inadvertently rotates, undesired friction occurs between the heat releaser and the inner shell.  
           [0019]    Preferably, the heat releaser has a curved outer surface conforming to the inner surface of the inner shell so as to prevent any gap from occurring therebetween and reducing the efficiency of heat transfer.  
           [0020]    The electronic device can be housed in a container, for example, made of plastics, and the container is housed within the roller body together with the heat releaser, which is exposed to both inside and outside the container to prevent heat buildup in the container. The container is preferably provided with an opening such as an aperture or cutout into which the heat releaser is inserted.  
           [0021]    Preferably, the fixed shaft has an internal bore through which a cable for supplying electrical current to the motor in the driving portion runs. Such a structure can be employed when main components are housed in a unit. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0022]    [0022]FIG. 1 is a cross-sectional view of the motorized roller of an embodiment of this invention;  
         [0023]    [0023]FIG. 2 is an exploded perspective view of the motorized roller illustrated in FIG. 1;  
         [0024]    [0024]FIG. 3 is a perspective view of the unit for the motorized roller illustrated in FIG. 1;  
         [0025]    [0025]FIG. 4 is a sectional view of the unit for the motorized roller illustrated in FIG. 1;  
         [0026]    [0026]FIG. 5 is a cross-sectional view of the unit taken along line A-A of FIG. 4;  
         [0027]    [0027]FIG. 6 is a perspective view of the motor driver assembly illustrated in FIG. 4;  
         [0028]    [0028]FIG. 7 is an enlarged perspective view of the motor driving circuit board  31  and the radiating plate  32  illustrated in FIG. 6; and  
         [0029]    [0029]FIG. 8 is an enlarged perspective view of the motor driving circuit board  31  and the radiating plate  32  of a modified example of this invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0030]    [0030]FIGS. 1 and 2 show a motorized roller  1  embodying the present invention. The motorized roller  1  is constructed in a unit  50  in which main components are housed, and the unit  50  is fixed to a cylindrical outer shell  13 , which is also called “roller body” or “external roller”.  
         [0031]    As illustrated in FIGS. 3 and 4, the unit  50  includes a cylindrical casing  2 , which, after assembly, acts as an inner shell of the motorized roller  1 , a fixed shaft  11  protruding from the casing  2 , a mechanical driving portion  3  built within the casing  2 , a rotating member  8  having a larger radius than that of the casing  2 , and a motor driver assembly  29  built within the casing  2  and controlling the mechanical driving portion  3 , wherein the rotating member  8  is rotated by force generated in the mechanical driving portion  3 .  
         [0032]    Briefly, the unit  50  has a casing  2 , which, after assembly, acts as an inner shell of the motorized roller  1 , and a mechanical driving portion  3  and a motor driver assembly  29 , which are mounted within the casing  2 . The mechanical driving portion  3  specifically consists of an electrical motor  4  and a speed reducer  5 .  
         [0033]    The rotating member  8  is equipped at one end of the casing  2 , slightly projecting radially from the casing  2 , whereas the fixed shaft  11  externally protrudes from the other end of the casing  2 . The rotating member  8  is engaged with a rotatable shaft  6 , which will be hereinafter called “output shaft  6 ”, extending from the mechanical driving portion  3  and protruding from the casing  2 . The output shaft  6  and the fixed shaft  11  are mounted on the ends of the casing  2  by means of a output shaft holder  7  and a fixed shaft holder  10 , respectively.  
         [0034]    More particularly, the casing  2  is made of a metal cylinder having open ends. The shaft holder  7  is made of plastics. The shaft holder  7  is practically of cylindrical shape with an outer diameter substantially equal to the inner diameter of the casing  2 . The holder  7  is fitted into an end portion (left end portion in FIGS. 3 and 4) of the casing  2 .  
         [0035]    The holder  7  has a pair of bearings  14  incorporated therein and disposed in series. Each of the bearings  14  has an inner diameter substantially equal to the diameter of the output shaft  6  and supports the shaft  6  rotatably so that the shaft  6  can rotate relative to the casing  2 .  
         [0036]    The fixed shaft holder  10  is also practically of cylindrical shape and is fitted into an end portion (right end portion in FIG. 4) of the casing  2 .  
         [0037]    The fixed shaft holder  10  has an inner diameter substantially equal to the diameter of the fixed shaft  11  so that the holder  10  fixes the shaft  11  to the casing  2  in an integral unit. More specifically, the holder  10  has no bearing interposed, and unifies the shaft  11  and the casing  2  as an integral and inseparable unit.  
         [0038]    The rotating member  8  is practically of cylindrical shape and has an outer diameter larger than that of the casing  2 . The rotating member  8  is made of zinc die cast.  
         [0039]    When the rotating member  8  is to be fitted into the outer shell  13 , the cylindrical surface of the member  8  is cut, scraped or ground and adjusted so that the outer diameter of the member  8  is substantially equal to the inner diameter of tie outer shell  13 .  
         [0040]    The rotating member  8  has an internal gear  16  coaxial therewith. The internal gear  16  is provided so that rotational force of the output shaft  6 , driven through the motor  4 , is transmitted efficiently to the rotating member  8 .  
         [0041]    The output shaft  6  is supported rotatably relative to the casing  2  through the shaft holder  7  and disposed coaxial with the unit  50 . The shaft  6  has an external gear  17  on the end portion thereof The external gear  17  is formed to be in mesh with the internal gear  16 .  
         [0042]    In the illustrated roller  1  the output shaft  6  and the rotating member  8  are joined together by means of gears, but instead of gears, a key or a spline can be used.  
         [0043]    A circular groove  15  is formed on the end portion of the output shaft  6 . A C-ring  9  is fitted into the groove  15  to protect the rotating member  8  from dropping out of the shaft  6 . More specifically, the rotating member  8  is detachably mounted on the output shaft  6  and a C-ring is fitted outside the member  8  to protect the member  8  from dropping out.  
         [0044]    The fixed shaft  11  is disposed at the end portion of the unit  50  and secured integrally to and coaxially with the casing  2  through the fixed shaft holder  10 . The fixed shaft  11  has an elongated axial bore, through which a cable  12  for feeding electric current runs. The cable  12  is connected to the motor driver assembly  29 , through which the current is supplied to the driving portion  3 .  
         [0045]    The fixed shaft  11  has a hexagonal shape in cross section at either of end portions  21 ,  22 . A circular cross section portion  23  with a smooth surface is formed between the hexagonal cross section portions  21 ,  22 . One end portion  21  with hexagonal section is supported relatively unrotatably through the fixed shaft holder  10 . The other end portion  22  with hexagonal section is used for securing the motorized roller  1  to a foreign member such as a conveyor frame after completing the motorized roller  1  by inserting the unit  50  into the outer shell  13 .  
         [0046]    The portion  23  with circular cross section contacts with a bearing  56  of an outer shell holder  51  as the unit  50  is inserted into the outer shell  13 .  
         [0047]    The motor driver assembly  29  includes a driver casing  30 , a pair of driver circuit boards  31  and a heat radiating plate  32 .  
         [0048]    The driver casing  30  functions as a container for electronic devices. The driver casing  30  is a virtually cylindrical member made of plastic with an outer diameter substantially equal to the inner diameter of the cylindrical casing  2 . The cylindrical surface of the driver casing  30  has a cutout  34 . A heat radiating plate  32  is mounted on the driver circuit board  31  and the board  31  is inserted into the driver casing  30  through the cutout  34 . Therefore, the width and the length of the cutout  34  are substantially equal to, or slightly larger than, those of the plate  32 . Receptacles  33  consisting of two pairs of grooves parallel with each other are formed on the inner surface of the driver casing  30 . As illustrated in FIG. 5, the receptacles  33  support a pair of the driver circuit boards  31  parallel to an X axis.  
         [0049]    In the illustrated examples, the cross section of the heat radiating plate  32  appears as if it were folded. The heat radiating plate  32  includes a planar wall  42  and a cylindrical wall  43  facing thereto with a clearance between them. A joint wall  41  connects between them. The planar wall  42  is contained within the driver casing  30  and an outer surface of the planar wall  42  is exposed to the inner space of the driver casing  30 , which is a container for electronic devices. The planar wall  42  is m contact with the electronic devices on the driver circuit board  31  within the driver casing  30 . The outer surface of the cylindrical wall  43  can be seen from outside the driver casing  30  through the cutout  34 . As the curvature of the outer surface of the cylindrical wall  43  which can be seen from outside of the driver casing  30  is substantially identical to the curvature of the outer surface of the driver casing  30 , the portion conforms smoothly to the outer surface of the driver casing  30 .  
         [0050]    The radiating plate  32  is made of metal, unlike the driver casing  30 . The planar wall  42  has a plurality of threaded bores  35  so that electronic devices on the driver circuit board  31  are secured to the wall  42 .  
         [0051]    Electronic devices for controlling the motor  4  are mounted on the driver circuit board  31 . The electronic devices include transistors  36 , operational amplifiers, logical circuits, etc. Two driver circuit boards  31  are contained within a driver casing  30 .  
         [0052]    Each transistor  36  in his invention has on its back an electrode  37 , which has a through-hole  38  for securing the transistor  36  to the radiating plate  32 . In most cases, a collector electrode should be selected as the electrode  37 .  
         [0053]    For assembling the driver assembly  29 , transistors  36  on the driver circuit board  31  are secured to the radiating plate by means of screws through the through-hole  38 . Then edges of the driver circuit boards  31  are inserted into the receptacles  33  so that the radiating plate  32  is contained within the cutout  34 .  
         [0054]    Preferably thermally conductive grease may be applied between the transistors  36  and the radiating plate  32 .  
         [0055]    In case the collector electrodes is short-circuited when the transistors  36  are secured to the radiating plate  32  by means of screws and holes  35 ,  38 , an electrical insulating film  39  can be sandwiched between the transistors  36  and the radiating plate  32  as illustrated in FIG. 8, and to increase heat conductivity silicone grease which has relatively high thermal conductivity is applied to at least one surface of the film  39 . Preferably electrical insulating caps  40  may be disposed between the holes  38  and the screws.  
         [0056]    The driver assembly  29  is so constructed that the outer surface of the cylindrical wall  43  of the radiating plate  32  contacts the inner surface of the cylindrical casing  2 . Therefore, the radiating plate  32  contacts the electronic devices such as the transistors  36  inside the driver casing  30  and contacts the casing  2  outside the driver casing  30 .  
         [0057]    The driving portion  3  is composed of an electric motor  4  and a speed reducer  5 . The motor  4  includes a rotor  27  utilizing permanent magnets and disposed on the central axis and a stator  28  formed of coils surrounding the rotor  27 . Hall elements (not shown) are utilized for pole detectors of the motor.  
         [0058]    The speed reducer  5 , intervening between the motor  4  and the output shaft  6 , transmits torque from the motor  4 , reducing the rotational speed.  
         [0059]    The rotation of the motor  4  is entirely controlled through the driver circuit board  31  of the driver assembly  29 .  
         [0060]    The illustrated roller  1  includes the unit  50  and the outer shell  13  to build the unit therein.  
         [0061]    More specifically, the motorized roller  1  utilized in this invention is constructed by inserting the unit  50  into the outer shell  13  having desired shape, length and thickness.  
         [0062]    Now, the manner of assembling the motorized roller  1  is described.  
         [0063]    A user of the motorized roller  1  separately provides the outer shell  13  and outer shell holders  25 ,  51  to be equipped on both ends of the outer shell  13 . The cross sectional shape, length and thickness of the outer shell  13  may be determined at discretion. As illustrated in the left side of FIG. 1, one outer shell holder  25  is constructed by integrating a cylindrical plug  24  to be fitted into the outer shell  13 , a pair of bearings  26  disposed in series and a fixed shaft  53 . As illustrated in the right side of FIG. 1, the other outer shell holder  51  is constructed by integrating a cylindrical plug  55  to be fitted into the outer shell  13  and a bearing  56 .  
         [0064]    Before inserting the unit  50  into the outer shell  13 , the outer diameter of the rotating member  8  of the unit  50  is adjusted to the inner diameter of the outer shell  13  by machining.  
         [0065]    In detail, at first the C ring  9  is detached from the output shaft  6 , and then the rotating member  8  is separated from the output shaft  6 . Then an outer surface of the rotating member  8  is cut, scraped or ground by means of a lathe or other machine tool so that the outer diameter of the member  8  is substantially identical to the inner diameter of the outer shell  13 .  
         [0066]    After finishing the machining, the rotating member  8  is put back so that it engages again with the output shaft  6  and the C ring  9  is attached to the output shaft  6 .  
         [0067]    Then, as illustrated in FIG. 2, the casing  2  of the unit  50  is inserted into the outer shell  13  so that the rotating member  8  contacts and engages with an inner surface of the outer shell  13 . Preferably the engagement of the rotating member  8  with the outer shell  13  is strengthened by caulking the outer shell  13  from outside or by punching the outer shell  13 , if necessary. Pins may be inserted between the rotating member  8  and the outer shell  13 , if necessary.  
         [0068]    Then outer shell holders  25 ,  51  are equipped on both ends of the outer shell  13 . In detail, as illustrated in FIGS. 1 and 2, the outer shell holder  25 , which is constructed by integrating the cylindrical member  24 , the bearings  26  and the fixed shaft  53 , is equipped on the end near the rotating member  8 . On the other hand, the outer shell holder  51 , which is constructed by integrating the cylindrical member  55  and the bearing  56 , is equipped on the fixed shaft  11 , with the fixed shaft  11  inserted into the inner ring of the bearing  56  and with the round cross section portion  23  contacting the inner side of the inner ring.  
         [0069]    The motorized roller  1  is assembled by the procedures described above.  
         [0070]    After securing the unit  50  within the outer shell  13  and the outer shell holder  25 ,  51  to the outer shell  13 , as electric power is supplied to the motor driver circuit board  31  and the driving portion  3 , the rotor  27  of the motor  4  rotates about an axis due to change of magnetic flux. The speed reducer  5  gains torque from the rotor  27  and reduces rotation. The torque is further transmitted through the output shaft  6  to the rotating member  8  engaging with the shaft  6 .  
         [0071]    As the outer shell  13  is supported on the bearings  26 ,  56  rotatably relative to the fixed axes  11 ,  53 , if the axes  11 ,  53  are secured to other unrotatable members, the outer shell  13  solely rotates relative to the axes by receiving power from the driving portion  3 .  
         [0072]    The inner shell casing  2  does not rotate with the outer shell  13 , for the casing  2  is integral with the fixed axis  11 .  
         [0073]    In this embodiment, the driver circuit board  31  equipped within the outer shell  13  is fed with electricity through the cable  12  and controls current outputted to the motor  4  in response to conditions of the motor  4 .  
         [0074]    Therefore, electronic devices such as the transistors  36  mounted on the driver circuit boards  31  generate heat in operation.  
         [0075]    As an internal resistance of semiconductor, contrary to metal, generally decreases with higher temperatures, if the temperature of the electronic devices are raised, too much electric current may be passed through the electronic devices, resulting in failure of control. To avoid such failure, in the illustrated roller  1 , a radiating plate  32  is attached to the transistors  36  which generate heat, to conduct heat out of the driver assembly  29 .  
         [0076]    More specifically, in the motorized roller  1 , as the heat-generating transistors  36  contact the radiating plate  32 , which in turn contacts the inner shell casing  2 , which has a larger radiating surface, heat generated in the transistors  36  is conducted through the radiating plate  32  and the inner shell casing  2  and dissipated externally.  
         [0077]    More specifically, in the illustrated motorized roller  1 , part of heat generated in the transistors  36  is dissipated externally directly through the radiating plate  32  and the other part of the heat is dissipated externally through the radiating plate  32  and the inner shell casing  2 . Therefore, in the illustrated motor  1 , the radiating plate  32  functions also as a heat conducting member.  
         [0078]    In the motorized roller  1 , heat generated in the transistors  36  can be conducted to the inner shell casing  2 , as the radiating plate  32  made of metal contacts both the transistors  36  and the casing  2  when the driver assembly  29  is held within the casing  2 .  
         [0079]    By incorporating the driver circuit board  31  into the motorized roller, an improvement of labor efficiency and apparent simplicity and neatness are attained. Stabilized control is also attained since heat generated in the driver assembly  29  is dissipated externally through radiating plate  32 .  
         [0080]    Though the outer shell  13  and the rotating member  8  are engaged directly in the embodiment described above, another member or other members may intervene between the outer shell  13  and the member  8  for the sake of self-aligning of the axes.  
         [0081]    The motorized roller  1  utilizes the unit  50  comprising a set of integrated members and functioning as both a power-generating unit and a power-transmitting unit. By utilizing the unit  50 , a desired motorized roller can be fabricated at user&#39;s discretion.  
         [0082]    As described above, the motorized roller  1  facilitates external wiring, by reducing the number of lead wires connected out of the roller, and assembling the roller to other components or parts.  
         [0083]    Also in this invention, heat generated in the electronic devices contained in the motorized roller is dissipated externally through the radiating plate to protect the devices from damage and avoid failure of control.  
         [0084]    In this way, the motorized roller of this invention enhances operational efficiency and outward simplicity and ensures safe control in operation.  
         [0085]    It is to be understood that the invention is not limited to the specific embodiments thereof Many apparently widely different embodiments of this invention may be made without departing from the spirit and scope thereof