Patent Description:
Roller conveyors are known among the systems for moving loads and goods.

Roller conveyors usually comprise a support frame onto which there are connected at least one motorized roller or motoroller, a plurality of idle rollers and/or a plurality of driven rollers, and a motion transmission system, e.g., at least one transmission belt or chain, which allows transferring the motion from said at least one motorized roller, directly or indirectly, to the plurality of driven rollers by means of said at least one belt or chain.

In particular, the motorized roller or motoroller comprises a hollow cylinder, in which a motor is arranged, which allows rotating the hollow cylinder with respect to the frame.

In some known solutions, the motor is arranged inside the hollow cylinder so as to transmit the drive torque to the roller by friction coupling. Some solutions of this type are know from <CIT>, <CIT>, <CIT>, <CIT> and <CIT> which shows the preamble of claim <NUM>.

Such solutions envisage the use of gaskets or contacts that work by friction in order to transmit the motion or rotation torque from the motor to the inner diameter of the roller or motoroller cylinder. Such gaskets comprise or consist of elastomers, therefore as they work by friction they can lose effectiveness, undermining the transmission of the motion from the motor to the roller or motoroller cylinder, i.e. reducing, if not cancelling out, the effectiveness of the transmission of motion from the motoroller to the driven rollers. Additionally, the loss of effectiveness of the gaskets over time, reduces the control of the material conveyed by the roller conveyor, with potential danger to the integrity of the conveyed materials and the people located in the vicinity of the roller conveyor. Hence, to overcome the loss of effectiveness of such gaskets, it is necessary to replace the motor, even if it is still operational, from the roller cylinder in order to be able to restore the correct transmission of movement from the motor to the roller cylinder. Such operations are very time consuming in terms of machine downtime, with consequent economic losses.

Therefore, a very strongly felt need in the sector is to reduce as much as possible the times and costs deriving from machine downtime, providing an effective and innovative system for transmitting motion from the motor to the roller cylinder with respect to the prior art.

In particular, the need is strongly felt to devise technical solutions that enable a significant reduction in events in which it is necessary to extract the motor from the roller, doing everything possible to limit operations on the motor to routine maintenance and any motor breakdowns.

Additionally, there is a strongly felt need to produce motor cartridges adapted to be inserted into a roller that maintain high operating reliability.

Therefore, the problem underlying the present invention is to devise a roller, which has such structural and functional features as to satisfy the aforementioned requirements and, at the same time, solve the drawbacks mentioned with reference to the prior art and satisfy the aforesaid needs felt.

The present invention sets out to provide a roller which have such structural and functional features as to satisfy the aforementioned requirements and, at the same time, solve the drawbacks mentioned with reference to the prior art and satisfy the aforesaid needs felt.

This and other objects and advantages are achieved with a roller according to claim <NUM>.

Some advantageous embodiments are the object of the dependent claims.

From the analysis of this situation it has emerged how the proposed solution enables a roller to be produced constituting a single component for the end customer with respect to the prior art, enabling a reduction in the probability of the roller breaking down and therefore a reduction in machine downtime.

Additionally, the proposed solution enables selfsupporting motor cartridges to be produced at just one end of the cartridge body.

According to some solutions, the motor cartridge envisages a single bearing which internally supports the stator of the motor unit and externally supports the rotor or gear motor of the motor unit, through which the drive torque can be transferred to the roller and at the same time support the roller, the motor unit and the cartridge body.

Additionally, the proposed solutions enable the reliability and versatility of motorized rollers provided with a motor cartridge to be increased and machine downtime to be significantly reduced.

Further features and advantages of the roller will become apparent from the description provided below of preferred exemplary embodiment thereof, given by way of non-limiting example, with reference to the accompanying drawings, in which:.

According to a general embodiment, a motor cartridge for a roller is generally indicated by reference numeral <NUM>.

Said motor cartridge <NUM> comprises a cartridge body <NUM> and a motor unit <NUM>.

Said cartridge body <NUM> is elongated and extends along an axial direction A-A between a first cartridge body end <NUM> and a second cartridge body end <NUM>.

Said motor unit <NUM> is exclusively supported at said first cartridge body end <NUM>.

In accordance with the invention, said motor unit <NUM> is connected to said cartridge body <NUM> and its entire weight is exclusively supported at said first cartridge body end <NUM>.

Said motor cartridge <NUM> is connected to a roller <NUM> exclusively by said first cartridge body end <NUM> leaving said cartridge body end <NUM> in a cantilever manner.

Advantageously, said motor unit <NUM> is adapted to transmit a rotation torque to said roller <NUM> by shape coupling exclusively through said first cartridge body end <NUM>.

Within this document, cartridge body <NUM> in a cantilever manner not only means that the cartridge body is firmly connected to the roller through said first cartridge body end <NUM> but also that other parts of the cartridge body, e.g. its cantilever portion, could indirectly or directly contact the roller <NUM>. In any case, the motor cartridge <NUM> transmits the drive torque generated by the motor unit <NUM> to the roller <NUM> exclusively by said first cartridge end <NUM>.

According to an embodiment, said motor cartridge <NUM> comprises a cartridge bearing <NUM>. Said cartridge bearing <NUM> is arranged at least at said first cartridge body end <NUM> and said cartridge bearing <NUM> connects said motor unit <NUM> to said cartridge body <NUM> at said first cartridge body end <NUM>.

According to an embodiment, said cartridge bearing <NUM> is the only bearing which connects said motor unit <NUM> to said cartridge body <NUM>.

According to an embodiment, said cartridge body <NUM> comprises a head <NUM>, wherein said head <NUM> is rotary and is arranged at said first cartridge body end <NUM>.

According to an embodiment, said head <NUM> is adapted to be connected to said roller <NUM> by supporting said motor cartridge <NUM> in a cantilever manner. According to an embodiment, said head <NUM> is adapted to be connected to said roller <NUM> at least by geometric coupling or shape coupling. According to an embodiment said head <NUM> is adapted to be connected to said roller <NUM> by interference.

According to an embodiment, said motor unit <NUM> comprises a motor comprising a stator <NUM> and a rotor <NUM>, wherein said rotor <NUM> is internal to said stator <NUM> or vice versa.

According to an embodiment, said cartridge bearing <NUM> is arranged between said stator <NUM> and said cartridge body <NUM> at said first cartridge body end <NUM>.

According to an embodiment, said cartridge bearing <NUM> is arranged between said stator <NUM> and said head <NUM>.

According to an embodiment, said head <NUM> comprises an axial head opening <NUM> in which said cartridge bearing <NUM> is accommodated.

According to an embodiment, said stator <NUM> comprises at least one portion arranged inside said axial head opening <NUM>.

According to an embodiment, said rotor <NUM> is connected to said cartridge body <NUM> at least at said second cartridge end <NUM>.

According to an embodiment, said stator <NUM> is supported by an internal bearing slewing ring <NUM> of said cartridge bearing <NUM>. According to an embodiment, said stator <NUM> is fitted onto said internal bearing slewing ring <NUM>.

According to an embodiment, said rotor <NUM> is supported, directly or indirectly, by an external bearing slewing ring <NUM> of the same cartridge bearing <NUM>.

According to an embodiment, said stator <NUM> comprises a stationary shaft <NUM>. According to an embodiment, said stationary shaft <NUM> is adapted to be connected to a structure of a roller conveyor so as to fasten said roller <NUM> to said roller conveyor. In other words, said stationary shaft <NUM>, when said motor cartridge <NUM> is connected to said roller <NUM>, forms the fastening shaft or stationary fastening portion of said roller <NUM>. According to an embodiment, said cartridge bearing <NUM> is arranged between said stationary shaft <NUM> and said head <NUM>. According to an embodiment, said stator <NUM> is supported by said internal bearing slewing ring <NUM> of said cartridge bearing <NUM> through said stationary shaft <NUM>. According to an embodiment, said stationary shaft <NUM> is fitted onto said internal bearing slewing ring <NUM>.

According to an embodiment, said stator <NUM> comprises a stator body <NUM> firmly connected to said stationary shaft <NUM>. According to an embodiment, said stator body <NUM> comprises a stator base <NUM> adapted to axially close said stator body <NUM> in the direction of said first cartridge end <NUM>. According to an embodiment, said stator body <NUM> is cup-shaped. According to an embodiment, said stator body has a closed cylindrical tubular shape on one side from said stator base <NUM>. According to an embodiment, said stationary shaft <NUM> is connected to said stator base <NUM>. According to an embodiment, said rotor <NUM> is arranged inside said stator body <NUM>.

According to an embodiment, said motor comprises a pair of motor bearings arranged between said rotor <NUM> and said stator <NUM>.

According to an embodiment, said motor unit <NUM> comprises a gear motor <NUM> connected to said rotor <NUM>.

According to an embodiment, said rotor <NUM> comprises a rotor shaft coupled to said gear motor <NUM>.

According to an embodiment, said gear motor <NUM> comprises a plurality of gears or toothed wheels accommodated in a reducer housing. According to an embodiment, said gear motor <NUM> is a planetary gear motor. According to an embodiment, said gear motor <NUM> comprises an end flange <NUM> which closes the reducer housing in the direction of said second cartridge end <NUM>. According to an embodiment, said gear motor <NUM> comprises a gear motor shaft <NUM>, or low speed shaft, connected by coupling to said end flange <NUM>.

According to an embodiment, said gear motor <NUM> is connected to said cartridge body <NUM> at said second cartridge end <NUM>.

According to an embodiment, said motor unit <NUM> comprises a brake. According to an embodiment, said brake is an electromagnetic brake. According to an embodiment, said brake is an electromagnetic brake. According to an embodiment, said motor unit <NUM> comprises an encoder or an electronic control and management unit configured to control said brake and said motor.

According to an embodiment, said cartridge body <NUM> comprises a transmission tube <NUM> which connects said second cartridge body end <NUM> and said first cartridge body end <NUM>.

According to an embodiment, said motor unit <NUM> is housed inside said transmission tube <NUM>.

According to an embodiment, said transmission tube <NUM> comprises a plurality of holes <NUM> for ventilating and cooling said motor unit <NUM>. According to an embodiment, wherein said transmission tube <NUM> rotates integrally with said roller <NUM> with respect to said stationary shaft <NUM> which remains still, and thanks to the plurality of holes <NUM> a flow of air is formed for cooling the motor unit <NUM>.

According to an embodiment, said transmission tube <NUM> is cylindrical and tubular.

According to an embodiment, said cartridge body <NUM> comprises a sleeve <NUM> at said second cartridge body end <NUM>, wherein said sleeve <NUM> is opposite to said head <NUM>, wherein said motor unit <NUM> is directly connected to said sleeve <NUM>.

According to an embodiment, said sleeve <NUM> comprises a coupling portion of sleeve <NUM> adapted to be coupled, in the axial direction A-A, to the end flange <NUM> of the gear motor <NUM> or to the gear motor shaft, or low speed shaft. According to an embodiment, the end flange <NUM> is axially connected to the coupling portion of sleeve <NUM> through connection means <NUM>, preferably threaded connection means.

According to an embodiment, said transmission shaft <NUM> is coupled at opposite ends at least by shape coupling to said head <NUM> and to said sleeve <NUM>.

According to an embodiment, said head <NUM> and said sleeve are shaped like caps that are coupled to corresponding side openings of the cylindrical transmission tube <NUM>.

According to an embodiment, said head <NUM> is fitted to said external bearing slewing ring <NUM>.

According to an embodiment, said transmission shaft <NUM> is fitted at opposite ends to said head <NUM> and to said sleeve <NUM>.

According to an embodiment, said head <NUM>, said transmission tube <NUM>, said sleeve <NUM>, said cartridge bearing <NUM>, and said motor unit <NUM> are coaxial.

According to an embodiment, said head <NUM> comprises a first head portion <NUM> adapted for shape coupling to said roller <NUM>.

According to an embodiment, said head <NUM> comprises a first head portion <NUM> adapted to be coupled by interference and/or gluing to said transmission tube <NUM>.

According to an embodiment, said second head portion <NUM> is adapted to be coupled to an inner surface <NUM> of said transmission tube <NUM>.

According to an embodiment, said head <NUM> comprises a plurality of first head teeth <NUM> adapted to be shape coupled to said transmission tube <NUM>.

According to an embodiment, said transmission tube <NUM> comprises first transmission tube seats <NUM> counter-shaped with respect to said first head teeth <NUM>.

According to an embodiment, said first head teeth <NUM> are inserted by shape coupling into said counter-shaped first transmission tube seats <NUM> so that said transmission tube <NUM> transmits said rotation torque from said motor unit <NUM> to said head <NUM>.

According to an embodiment, said first head portion <NUM> comprises a plurality of second head teeth <NUM> adapted to be shape coupled to a roller body <NUM> of said roller <NUM>. According to an embodiment, said roller body <NUM> at said first roller end <NUM>, i.e. where said head <NUM> is coupled, comprises roller body seats <NUM> counter-shaped with respect to said second head teeth <NUM>. According to an embodiment, said second head teeth <NUM> are inserted into said counter-shaped roller body seats <NUM>, so that said motor cartridge <NUM> transmits said rotation torque from said motor unit <NUM> to said roller body <NUM> exclusively at said first roller end <NUM>.

According to an embodiment, said head <NUM> comprises a third head portion <NUM> adapted to be coupled by interference and/or by gluing to an inner roller surface <NUM> of said roller body <NUM>.

According to an embodiment, said sleeve <NUM> comprises a first portion of sleeve <NUM> configured to center said cartridge inside said roller <NUM> avoiding the transmission of any drive torque to said roller <NUM>. According to an embodiment, said first sleeve portion <NUM> contacts or rests, directly or indirectly, inside said roller <NUM>, avoiding the creation of a coupling adapted to transmit said rotation torque from said motor unit <NUM> to said roller <NUM> at said sleeve (<NUM>).

According to an embodiment, said sleeve <NUM> comprises a second sleeve portion <NUM> adapted to be coupled by interference and/or gluing to said transmission tube <NUM>. According to an embodiment, said second sleeve portion <NUM> is coupled to a transmission tube inner surface <NUM> of said transmission tube <NUM>.

According to an embodiment, said sleeve <NUM> comprises a plurality of sleeve teeth <NUM> adapted to be shape coupled to said transmission tube <NUM>.

According to an embodiment, said transmission tube <NUM> comprises second transmission tube seats <NUM> counter-shaped with respect to said head teeth <NUM>.

According to an embodiment, said sleeve teeth <NUM> are inserted into said counter-shaped second transmission tube seats <NUM> so that said sleeve <NUM> transmits said rotation torque from said motor unit <NUM> to said transmission tube <NUM>.

According to an embodiment, said first transmission tube seats <NUM> and said second transmission tube seats <NUM> are made at diametrically opposite ends along the axial direction A-A of said transmission tube <NUM>.

According to an embodiment, said axial direction A-A defines a radial direction R-R orthogonal to said axial direction A-A. According to an embodiment, said axial direction A-A defines a circumferential direction C-C orthogonal to said axial direction A-A and said radial direction R-R.

According to an embodiment, said first head teeth <NUM> and/or said second head teeth <NUM> and/or said sleeve teeth <NUM> each have a tooth body that projects in a radial direction R-R with respect to the head <NUM> or to the sleeve <NUM>, wherein said tooth body extends mainly in the axial direction A-A.

According to an embodiment, said first transmission tube <NUM> and/or second transmission tube seats <NUM> and/or said roller body seats <NUM> form slots or discharges in the thickness of the transmission tube body <NUM> or in the roller body <NUM> having a prevalent extension in the axial direction A-A, wherein said slots or discharges are delimited in the circumferential direction C-C of the transmission tube body <NUM> or by the roller body <NUM> so that said rotation torque is transmitted by the respective head teeth <NUM>, <NUM> or by the respective shape-coupled sleeve teeth <NUM>.

According to an embodiment, said sleeve <NUM> comprises at least one annular sleeve seat <NUM> adapted to house a corresponding centering elastomer <NUM>. Such centering elastomer <NUM> is shaped so as to prevent any transmission of said rotation torque from the motor cartridge <NUM> to the roller <NUM>. According to an embodiment, said elastomer is an o-ring.

According to an embodiment, said sleeve <NUM> rests indirectly on an inner surface of said roller <NUM>, said sleeve <NUM> being free to rotate inside said roller <NUM> avoiding transmitting said rotation torque to said roller <NUM>.

According to an embodiment, said stationary shaft <NUM> is configured to be connected to a support frame or structure for said roller <NUM>.

Within this document, coupling by interference and/or gluing means a coupling, between two components of the motor cartridge <NUM> or of the motor cartridge <NUM> and the roller <NUM>, which prevents or limits any axial extraction along the direction A-A of one component with respect to another, which is unsuitable to transmit a rotation from one component to another.

As described above, the invention relates to a roller <NUM>.

Said roller <NUM> comprises a roller body <NUM> and at least one motor cartridge <NUM> in which said motor cartridge <NUM> is connected to said roller body <NUM> to place it in rotation.

According to the invention said roller body <NUM> extends between a first roller end <NUM> and a second roller end <NUM>, wherein said roller body <NUM> defines a motor cartridge seat <NUM> therein.

According to the invention, said motor cartridge <NUM> is connected to said roller body <NUM> at said first roller end <NUM> through said first cartridge body end <NUM> leaving said cartridge body <NUM> projecting in a cantilever manner into said motor cartridge seat <NUM>.

According to an embodiment, said motor cartridge <NUM> transmits a rotation torque to said roller <NUM> exclusively through said first cartridge body end <NUM>.

According to the invention, said roller body <NUM> at said first roller end <NUM> is rotationally supported by said cartridge bearing <NUM>.

According to an embodiment, said roller <NUM> comprises a transmission member <NUM> integrally connected to said roller body <NUM> at said second roller end <NUM>, wherein said transmission member <NUM> is configured to transmit a rotary motion to a driven roller.

According to an embodiment, said transmission member <NUM> is a chain gear and/or a pulley, e.g. a belt pulley.

According to an embodiment, said cartridge body <NUM> is connected to said roller body <NUM> at said first roller end <NUM> at least by shape coupling.

According to an embodiment, said roller body <NUM> at said first roller end <NUM> comprises roller body seats <NUM> counter-shaped with respect to said second head teeth <NUM>, so that as said second head teeth <NUM> are inserted into said counter-shaped roller body seats <NUM>, said motor cartridge <NUM> transmits said rotation torque from said motor unit <NUM> to said roller body <NUM> exclusively at said first roller end <NUM>.

According to an embodiment, said transmission member <NUM> comprises at least a first transmission element portion <NUM> adapted to be connected by interference to said roller body <NUM> or fastened by means of welding to said roller body <NUM>.

According to an embodiment, said transmission member <NUM> comprises at least a second transmission member portion <NUM> adapted to be connected by geometric coupling to said roller body <NUM>.

According to an embodiment, said transmission member <NUM> comprises an inner seat, in which a transmission member bearing <NUM> is accommodated.

According to an embodiment, said transmission member bearing <NUM> supports in rotation said roller <NUM> at said second roller end <NUM>.

Advantageously, thanks to the provision of a first cartridge body end <NUM> adapted to support the motor unit <NUM> of the motor cartridge <NUM> and adapted to connect at least by shape coupling the motor cartridge <NUM> to a roller <NUM> so that the cartridge body <NUM> is overhanging with respect to the roller <NUM>, it is possible to reduce the necessary components for the production of the motor cartridge <NUM> providing an extremely compact cartridge which is simple to replace in the event of any breakdown of the motor part.

Additionally, thanks to the provision of a motor unit <NUM> which is exclusively supported at said first end <NUM> and the provision of said first end <NUM> through which said motor cartridge <NUM> is adapted to be connected in a cantilever manner to said roller <NUM>, it is possible to transfer the motor torque from the motor to the roller in the same point in which the motor is supported.

Claim 1:
A roller (<NUM>) comprising
- a roller body (<NUM>) which extends between a first roller end (<NUM>) and a second roller end (<NUM>), wherein said roller body (<NUM>) defines a motor cartridge seat (<NUM>) therein,
- a motor cartridge (<NUM>) for a roller comprising:
- a cartridge body (<NUM>), wherein said cartridge body (<NUM>) is elongated and extends along an axial direction (A-A) between a first cartridge body end (<NUM>) and a second cartridge body end (<NUM>),
- a motor unit (<NUM>), wherein said motor unit (<NUM>) is supported at said first cartridge body end (<NUM>),
characterized in that
- said motor cartridge (<NUM>) is connected to said roller body (<NUM>) at said first roller end (<NUM>) through said first cartridge body end (<NUM>) leaving said cartridge body (<NUM>) projecting in a cantilever manner into said motor cartridge seat (<NUM>), wherein said motor cartridge (<NUM>) transmits said rotation torque to said roller (<NUM>) exclusively through said first cartridge body end (<NUM>).