A conveyor drive roller for moving a conveyor medium. The conveyor roller has a hollow drum which is rotatably connected to a first and a second stationary shaft. An internal gear assembly is disposed inside the hollow drum and couples a motor to the hollow drum such that operation of the motor caus
A conveyor drive roller for moving a conveyor medium. The conveyor roller has a hollow drum which is rotatably connected to a first and a second stationary shaft. An internal gear assembly is disposed inside the hollow drum and couples a motor to the hollow drum such that operation of the motor causes rotation of the hollow drum about the first and second stationary shafts. The hollow drum is configured to hold a liquid lubricant in contact with the internal gear assembly. Liquid lubricant flow paths are provided to move the liquid lubricant from inside the hollow drum to outside the hollow drum via the first or second stationary shafts, and vice versa. The liquid lubricant flow paths are configured for connection to a means for cooling the liquid lubricant.
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1. A conveyor drive roller for moving a conveyor medium, said conveyor drive roller comprising: a hollow drum rotatably connected to a first stationary shaft and a second stationary shaft;an internal gear assembly disposed inside said hollow drum, and operatively connected to said hollow drum, said
1. A conveyor drive roller for moving a conveyor medium, said conveyor drive roller comprising: a hollow drum rotatably connected to a first stationary shaft and a second stationary shaft;an internal gear assembly disposed inside said hollow drum, and operatively connected to said hollow drum, said internal gear assembly being configured to operatively couple to a motor, wherein when said motor is coupled to said internal gear assembly, operation of said motor causes rotation of said hollow drum about said first and second stationary shafts;a first liquid lubricant, flow path passing from inside said hollow drum to outside said hollow drum through said first or second stationary shaft, said first liquid lubricant flow path being configured to permit a liquid lubricant be moved from inside said hollow drum to outside said hollow drum; anda second liquid lubricant flow path passing from outside said hollow drum to inside said hollow drum through said first or second stationary shaft, said second liquid lubricant flow path being configured to permit said liquid lubricant be moved from outside said hollow drum to inside said hollow drum; andwherein said first and second liquid lubricant flow paths are configured to connect to a liquid lubricant cooler positioned outside of said hollow drum. 2. The conveyor drive as claimed in claim 1, wherein both said first and second liquid lubricant flow paths pass through the same first or second stationary shaft. 3. The conveyor drive as claimed in claim 1, wherein said first liquid lubricant flow path passes through of one of said first stationary shaft and said second stationary shaft, and said second liquid, lubricant flow path passes through the other of said first stationary shaft and said second stationary shaft. 4. The conveyor drive roller as claimed in claim 1, wherein said hollow drum further comprises said liquid lubricant. 5. The conveyor drive roller as claimed in claim 1, wherein said liquid lubricant is an oil. 6. The conveyor drive roller as claimed in claim 5, wherein said oil is EP220, or an industrial enclosed gear box lubricant. 7. The conveyor drive roller as claimed in claim 1, wherein said motor is an electric motor positioned inside or outside of said hollow drum. 8. The conveyor drive roller as claimed claim 1, wherein said first liquid lubricant flow path comprises an inlet inside said hollow drum, said inlet being positioned below a level of said liquid lubricant. 9. The conveyor drive roller as claimed claim 8, wherein said inlet is positioned toward a bottom of said hollow drum. 10. The conveyor drive as claimed in 1, wherein said second lubricant flow path comprises an outlet inside said hollow drum, said outlet being positioned to discharge liquid lubricant onto at least a portion of said internal gear assembly. 11. The conveyor drive roller as claimed in claim 1, wherein said first liquid lubricant flow path comprises an outlet positioned outside said hollow drum on said first or second stationary shaft, and wherein said second liquid lubricant flow path comprises an inlet positioned outside said hollow drum on said first or second stationary shaft. 12. The conveyor drive roller as claimed in claim 11, further comprising said liquid lubricant cooler operatively connected to said first and second liquid lubricant flow paths, wherein said liquid lubricant cooler comprises: a circulation pathway for said liquid lubricant, said circulation pathway being connected to said outlet of said first liquid lubricant flow path and said inlet of said second liquid lubricant flow path;a pump positioned on said circulation pathway to move said liquid lubricant through said circulation pathway; anda heat exchanger positioned on said circulation pathway to cool said liquid lubricant as it moves through said heat exchanger. 13. The conveyor drive roller as claimed in claim 12, wherein said heat exchanger is an air-to-liquid heat exchanger, and said liquid lubricant cooler further comprises a fan to move air through said air-to-liquid heat exchanger. 14. The conveyor drive roller as claimed in claim 1, wherein said liquid lubricant cooler is capable of cooling said liquid lubricant to below a critical temperature. 15. The conveyor drive roller as claimed in claim 14, wherein said critical temperature is a temperature at which said liquid lubricant degrades or components of said conveyor drive roller fail. 16. The conveyor drive roller as claimed in claim 12, wherein said liquid lubricant cooler is sized and configured to maintain said liquid lubricant inside said hollow drum at a temperature less than or equal to 90° C. 17. The conveyor drive roller as claimed in claim 12, wherein said liquid lubricant cooler is sized and configured to provide a heat rejection rate equal to or greater than a heat generation rate of the conveyor drive roller. 18. The conveyor drive roller as claimed in claim 12, wherein said liquid lubricant cooler is sized and configured to provide a heat rejection rate equal to or greater than the difference between a heat generation rate of the conveyor drive roller and a heat rejection rate of the conveyor drive roller. 19. The conveyor drive roller as claimed in claim 1, further comprising a means for measuring a temperature of the liquid lubricant inside of said hollow drum and turning the liquid lubricant cooler on and off in response to changes in said temperature of the liquid lubricant inside of said hollow drum. 20. A method of cooling a conveyor drive roller having a) a hollow drum rotatably connected to a first stationary shaft and a second stationary shaft, b) a liquid lubricant disposed inside said hollow drum, and c) an internal gear assembly disposed inside said hollow drum, and operatively connected to said hollow drum, said internal gear assembly being configured to operatively couple to a motor, wherein when said motor is coupled to said internal gear assembly operation of said motor causes rotation of said hollow drum about said first and second stationary shafts, said method comprising the step of: circulating said liquid lubricant inside of said hollow drum through a liquid lubricant cooler positioned outside of said hollow drum. 21. The method as claimed in claim 20, wherein said circulating step comprises: removing a portion of said liquid lubricant from inside said hollow drum to outside said hollow drum through said first or second stationary shaft via a first liquid lubricant flow path;cooling said portion of said liquid lubricant removed from inside said hollow drum;returning said portion of said cooled liquid lubricant from outside said hollow drum to inside said hollow drum through said first or second stationary shaft via a second liquid lubricant flow path. 22. The method as claimed in claim 21, wherein said liquid lubricant cooler comprises: a circulation pathway connected to said first liquid lubricant flow path and said second liquid lubricant flow path;a pump positioned on said circulation pathway to move said liquid lubricant through said circulation pathway; anda heat exchanger positioned on said circulation pathway to cool said liquid lubricant as it moves through said heat exchanger. 23. The method as claimed in claim 22, wherein said heat exchanger is an air-to-liquid heat exchanger, and said liquid lubricant cooler further comprises a fan to move air through said air-to-liquid heat exchanger. 24. The method as claimed in claim 22, wherein said lubricant cooler is capable of cooling said liquid lubricant circulated therethrough to maintain said liquid lubricant inside of said hollow drum below a critical temperature. 25. The method as claimed in claim 24, wherein said critical temperature is temperature at which said liquid lubricant degrades or components of said conveyor drive roller fail. 26. The method as claimed in claim 25, wherein said liquid lubricant cooler is sized and configured to maintain said liquid lubricant inside said hollow drum at a temperature less than or equal to 90° C. 27. The method as claimed in claim 22, wherein said liquid lubricant cooler is sized and configured to provide a heat rejection rate equal to or greater than a heat generation rate of the conveyor drive roller. 28. The method as claimed in claim 22, wherein said liquid lubricant cooler is sized and configured to provide a heat rejection rate equal to or greater than the difference between a heat generation rate of the conveyor drive roller and a heat rejection rate of the conveyor drive roller. 29. The method as claimed in claim 22, further comprising measuring said temperature of the liquid lubricant inside of said hollow drum and turning the liquid lubricant cooler on and off in response to changes in temperature of the liquid lubricant inside of said hollow drum. 30. The method as claimed in claim 22, wherein said motor is an electric motor positioned inside or outside of said hollow drum. 31. A method of making a conveyor drive roller in a size smaller than required to avoid overheating by intrinsic heat dissipation during continuous operation of said conveyor drive roller, the method comprising the steps of: forming a hollow drum with said smaller size and rotatably connecting said hollow drum to a first stationary shaft and a second stationary shaft, with an internal gear assembly disposed inside of said hollow drum and operatively connected to said hollow drum, said hollow drum being configured to hold a liquid lubricant in contact with said internal gear assembly, said internal gear assembly being configured to operatively couple to a motor, wherein when said motor is coupled to said internal gear assembly operation of said motor causes rotation of said hollow drum about said first and second stationary shafts; andconfiguring said first and/or second stationary shaft to permit circulation of said liquid lubricant inside of said hollow drum through a liquid lubricant cooler, wherein said liquid lubricant cooler is capable of cooling said liquid lubricant circulated therethrough to maintain a temperature of the liquid lubricant inside of said hollow drum below a critical temperature. 32. The method as claimed in claim 31, further comprising operatively connecting said liquid lubricant cooler to said configured first and/or second stationary shaft. 33. The method as claimed in claim 32, further comprising measuring said temperature of the liquid lubricant inside of said hollow drum and turning the liquid lubricant cooler on and off in response to changes in said temperature of the liquid lubricant inside of said hollow drum. 34. The method as claimed in claim 31, wherein said critical temperature is temperature at which said liquid lubricant degrades or components of said conveyor drive roller fail. 35. The method as claimed in claim 34, wherein said liquid lubricant cooler is sized and configured to maintain said liquid lubricant inside said hollow drum at a temperature of less than or equal to 90° C. 36. The method as claimed in claim 31, further comprising the steps of: estimating a heat generation rate of the conveyor drive roller; andselecting said liquid lubricant cooler to have a heat rejection rate equal to or greater than said estimated heat generation rate of the conveyor drive roller. 37. The method as claimed in claim 31, further comprising the steps of: estimating a heat generation rate of the conveyor drive roller;estimating a heat rejection rate of the conveyor drive roller; andselecting said liquid lubricant cooler to have a heat rejection rate equal to or greater than the difference between said estimated heat generation rate of the conveyor drive roller and said estimated heat rejection rate of the conveyor drive roller. 38. The method as claimed in claim 31, wherein said configuring said first and/or second stationary shaft step comprises: forming a first liquid lubricant flow path in said first or second stationary shafts for removing a portion of said liquid lubricant from inside said hollow drum;forming a second liquid lubricant flow path in said first or second stationary shaft for returning said portion of said liquid lubricant to inside of said hollow drum. 39. The method as claimed in claim 38, wherein said liquid lubricant cooler comprises: a circulation pathway connected to said first liquid lubricant flow path and said second liquid lubricant flow path;a pump positioned on said circulation pathway to move said liquid lubricant through said circulation pathway; anda heat exchanger positioned on said circulation pathway to cool said liquid lubricant as it moves through said heat exchanger. 40. The method as claimed in claim 38, wherein said heat exchanger is an air-to-liquid heat exchanger, and said liquid lubricant cooler further comprises a fan to move air through said air-to-liquid heat exchanger. 41. The method as claimed in claim 31, wherein said motor is an electric motor positioned inside or outside of said hollow drum. 42. The method as claimed in claim 31, wherein said hollow drum is at least 20% smaller by volume than required to avoid overheating by intrinsic heat dissipation during continuous operation of said conveyor drive roller without the liquid lubricant cooler.
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