Fastener assembly for cable conveying belt and cable fastener

Abstract

The present application provides a fastener assembly for connecting a first cable end portion and a second cable end portion of a cable conveyor belt, and a cable fastener. The fastener assembly includes a first cable fastener having a first head portion and a first plurality of locking members for securing the first cable fastener to a first cable end portion. The fastener assembly includes a second cable fastener having a second head portion and a second plurality of locking members for securing the second cable fastener to a second cable end portion. The fastener assembly also includes a connector having a first pocket dimensioned to receive the first head portion and a second pocket dimensioned to receive the second head portion, the connector having a first recess dimensioned to receive the first head portion and a second recess dimensioned to receive the second head portion. The first and second pockets and the first and second head portions are configured to allow the first and second cable fasteners to move relative to the connector during operation of the cable conveyor belt.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 564,486, filed March 12, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to joints for conveyor belts, and more specifically, to joints for conveyor belts containing cables. Background Technology

[0004] Cable conveyor belts consist of rubber and cables embedded in the rubber, which extend along the length of the conveyor belt. The diameter of the cables typically ranges from 3 mm to 13 mm. The cables provide tensile strength to the conveyor belt as it is loaded with the material being transported and travels along its path, passing over pulleys. The tension in each cable is shared by the rubber extending between the cables and the nearby cables; when the cables are under tension, the rubber is subjected to shear forces.

[0005] Cable conveyor belts are typically used in heavy-duty applications. The loads carried by these belts are usually measured in tons. Furthermore, the belts are large, extending half a mile or more, and can be four feet or wider. Cable conveyor belts must possess high strength to withstand these operating conditions. In this respect, the rated working load range for cable conveyor belts can be from 800 psi (Per Inch Width, PIW) to 8500 PIW. Given the size and construction of cable conveyor belts, they are often difficult to repair when damaged. Cable conveyor belts can be damaged by, for example, a very heavy object falling onto the belt or an object tearing the belt.

[0006] Connecting the end of a new cable conveyor belt or repairing a severely damaged one is a complex process requiring advanced skills and specialized tools, and often results in extended downtime for the conveyor system. Traditional installation and maintenance agreements involve the factory shutting down the conveyor and requesting a professional team to come to the factory to repair the belt. However, if the factory using the cable conveyor belt is located in a remote area, the team may need to travel for several days to reach the factory.

[0007] When the maintenance team arrives at the factory, they typically set up a temporary shelter to protect the damaged section of the conveyor belt from environmental impact. The damaged section is identified, and then the entire damaged section is usually removed by completely cutting it off. This allows the ends of the conveyor belt to be joined together either by a single splice between the belt ends or by a new section of belt (sometimes called a "saddle"). When using a saddle to join the ends, the maintenance operation involves creating two splices: one between one belt end and the saddle, and another between the other belt end and the saddle.

[0008] For example, to prepare a vulcanized splice for a conveyor belt, the team first strips the over cover at the newly cut end of the remaining undamaged belt end, separates the cables from the under cover rubber at that end, and then strips the under cover at that end. Any rubber remaining on the cables is hand trimmed away. Each exposed cable is then cut to a predetermined length according to the splice instructions of the steel cable belt manufacturer. The process is repeated at the other end of the conveyor belt.

[0009] The team then places the lower platen of the vulcanizer under the prepared belt end. Vulcanizers for steel cable conveyor belts are typically very large and require the use of a crane to lift the vulcanizer into place. The cables of the belt end are cleaned and a special adhesive is applied to the cables in preparation for bonding the cables to the rubber of the splice. Next, the under cover of the splice is positioned under the cables and the cables are arranged in a pattern according to the splice instructions of the belt manufacturer. Uncured rubber strips, sometimes referred to as noodles, and gap fillers are used to fill the areas between the cables. The over cover of the splice is then positioned over the cables.

[0010] The upper platen of the vulcanizer is positioned over the over cover using a crane to sandwich the over cover, steel cables, and under cover between the upper and lower platens of the vulcanizer. The vulcanizer is operated to raise the temperature of the splice to a predetermined temperature and to compress the splice at a predetermined pressure. After the vulcanization process is complete, the team removes the upper platen using the crane. The splice is lifted off the lower platen so that the splice can cool. The lower platen is subsequently removed from the belt and the belt is ready for use. For higher tension belts, the splice length can be 15 feet or more and require multiple vulcanization cycles because the length of the vulcanizer is insufficient to heat the entire splice length and must be moved lengthwise along the splice length to heat the entire splice length.

[0011] As will be appreciated, the conventional method of repairing a steel cable conveyor belt using a vulcanized splice is labor intensive and time consuming and can take several days to get the belt back in operation. This downtime has a negative impact on the productivity of the facility, particularly for large operations that rely on the conveyor belt to transport several tons of aggregate or other material per hour.

[0012] U.S. Patent No. 11,022,197 to Dailey et al. discloses a mechanical splice for joining ends of a steel cable conveyor belt. The splice includes fasteners connected to cables that protrude outward from the belt ends. The fasteners have aligned loops to receive hinge pins of fasteners that connect the belt ends. The hinge pins can include cables with multi-strands that provide flexibility to the splice while being strong enough to resist loads applied to the hinge pins by the fasteners during operation of the steel cable belt.

[0013] Heavy duty steel cable conveyor belts have a breaking strength of 2500 N / mm or more and are subjected to high tension during operation of the conveyor due to the heavy loads being conveyed. Some commercially available hinge pins can not be able to withstand the extreme forces applied to the joint during operation of the conveyor belt. Thus, mechanical joints utilizing hinge pins can not be commercially practical for heavy duty steel cable conveyor belts.

[0014] Another problem with mechanical splicing of heavy duty steel cable conveyor belts is that the conveyor belt has large diameter cables, for example 8 mm or more, that are closely spaced on the conveyor belt to withstand the high working loads experienced by the conveyor belt. For example, a conveyor belt having a breaking strength of 2500 N / mm can have steel cables that are 6.4 mm in diameter and a pitch of 15 mm between the centers of adjacent cables, while a conveyor belt having a breaking strength of 3500 N / mm can have cables that are 8 mm in diameter and a pitch of 17 mm or less between the centers of adjacent cables. This relatively narrow spacing between the cables of a heavy duty steel cable conveyor belt makes it challenging to connect the ends of the heavy duty steel cable conveyor belt using mechanical joints. SUMMARY

[0015] In one aspect of the disclosure, a fastener assembly for connecting first and second cable end portions of a cable conveyor belt is provided. The fastener assembly includes a first cable fastener having a first head portion and a first plurality of locking members for securing the first cable fastener to the first cable end portion. The fastener assembly includes a second cable fastener having a second head portion and a second plurality of locking members for securing the second cable fastener to the second cable end portion. The fastener assembly further includes a connector having a first pocket sized to receive the first head portion and a second pocket sized to receive the second head portion, the first and second pockets and the first and second head portions being configured to allow the first and second cable fasteners to move relative to the connector during operation of the cable conveyor belt. The fastener assembly enables a secure connection between the cable end portions while allowing the first and second cable fasteners to move, for example when the fastener assembly and cable end portions are traveling around a pulley, which improves the durability of the fastener assembly.

[0016] The present disclosure also provides a cable fastener for connecting cable end portions of a conveyor belt. The cable fastener includes a body having a bore for receiving a cable end portion, an inner surface of the body extending around the bore, a plurality of narrow outer surfaces of the body, and a plurality of wide outer surfaces of the body alternating with the narrow outer surfaces around the body. The cable fastener also includes a plurality of rows of threaded through openings of the narrow outer surfaces extending to the inner surface. The cable fastener includes a set screw in the threaded through openings operable to secure the cable end portion into the bore. The body has thicker portions extending between the inner surface and the narrow outer surfaces to strengthen the body adjacent to the plurality of rows of threaded through openings. The body also includes thinner portions extending between the inner surface and the wider outer surfaces to allow the cable fastener to be positioned compactly adjacent to fasteners secured to adjacent cable end portions of the conveyor belt. In this way, one of the wide outer surfaces of the cable fastener can be positioned immediately adjacent to one of the narrow outer surfaces of a fastener secured to an adjacent cable end portion and avoid lateral displacement of the adjacent cable end portion due to contact between the cable fasteners.

[0017] According to another aspect of the present disclosure, a method for connecting cable end portions of a cable conveyor belt is provided. The method includes securing a cable fastener to a cable end portion, aligning a head portion of the cable fastener with a pocket portion of a connector member, and moving the connector member of the connector together such that the pocket portion extends around the head portion and forms a pocket of the connector. The method also includes securing the connector member together to capture the head portion of the fastener in the pocket of the connector. BRIEF DESCRIPTION OF DRAWINGS

[0018] FIG. 1 is an isometric view of a mechanical joint connecting ends of a heavy steel cable conveyor belt;

[0019] FIG. 2 is FIG. 1 is a cable plan view of two fastener assemblies of the joint of

[0020] FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 2 is a fastener assembly of one of the cable end portions connecting ends of a conveyor belt, the fastener assembly including two cable fasteners secured to two cable end portions and an intermediate connector connecting the two fasteners;

[0021] FIG. 4 is a cross-sectional view of one of the fasteners in FIG. 3 is a cross-sectional view of one of the fasteners in

[0022] FIG. 5 is a similar cross-sectional view showing the cable end portion bending in the fastener entry opening area as the joint travels around the pulley; FIG. 4

[0023] FIG. 6A is a cross-sectional view taken along line 6A-6A of FIG. 2 showing adjacent cable fasteners rotated offset relative to one another to allow close positioning of the cable fasteners secured to the cable without creating interference between the set screws of adjacent fasteners;

[0024] FIG. 6B is a cross-sectional view taken along line 6B-6B of FIG. 2 showing a thicker portion of the fastener body between the threaded openings receiving the set screws of the cable fastener;

[0025] FIG. 7 is an isometric view of the fastener assembly of FIG. 3 showing one cable fastener extending through the end entry of the link;

[0026] FIG. 8 is a front view of one cable fastener showing a distal head portion connected to a narrowed neck portion, wherein the head portion includes a stepped profile for engaging a corresponding stepped profile of the link pocket;

[0027] FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 7 showing the engagement curved surfaces of the fastener neck portion and the edge portion of the link, and the tapered guide surface of the fastener distal head portion that allows limited pivoting of the fastener relative to the link during the conveyor belt operation;

[0028] FIG. 10 is a front view of the inboard or proximal end of one cable fastener of FIG. 7 showing a blind hole for receiving an end portion of a cable, and a set screw driven to extend into the blind hole for engaging a bundle of the cable end portion;

[0029] FIG. 11 is a front view of the outboard or distal end of the cable fastener of FIG. 10 showing a truncated conical guide surface of the fastener;

[0030] FIG. 12 is an isometric view of the link of FIG. 7 showing the upper and lower link members secured together with screws;

[0031] FIG. 13 is a front view of the link of FIG. 12 ​is an exploded view of the connector showing the upper and lower concave recessed openings at the ends of the upper and lower connector members that cooperate to form the end entry opening of the connector for receiving the neck portion of one of the fasteners at its respective end;

[0032] FIG. 14 is a bottom plan view of the upper connector member showing the recessed pocket portions formed at its two ends;

[0033] FIG. 15 is FIG. 13 is a top plan view of the lower connector member showing the lower semi-circular recessed pocket portions formed at its two ends that cooperate with the recessed pocket portions of the upper connector member to form the pocket of the connector for receiving the head portion of the cable fastener;

[0034] FIG. 16 is a cross-sectional view taken along line 16-16 of FIG. 12 is a cross-sectional view taken along line 16-16 of

[0035] FIG. 17 is a perspective view of a replacement fastener for repairing a damaged steel cable conveyor belt;

[0036] FIG. 18 is FIG. 17 is an end elevational view of the fastener showing the bore for receiving the cable end portion and the set screw driven to extend into the bore for engaging the cable end portion;

[0037] FIG. 19 is a cross-sectional view taken along line 19-19 of FIG. 17 is a cross-sectional view taken along line 19-19 of

[0038] FIG. 20A is a flowchart of a method of repairing a bore in a steel cable conveyor belt using the same fastener as FIG. 17

[0039] FIG. 20B-FIG. 27 is a plan and cross-sectional view of a portion of a steel cable conveyor belt illustrating the method of FIG. 20A

[0040] is a flowchart of a method of applying a fastener to a cable end portion of a conveyor belt; FIG. 28A

[0041] is a cross-sectional view of a cable end portion and a fastener illustrating the method of FIG. 28B-FIG. 32 FIG. 28A

[0042] ​​​FIG. 33A is a flowchart of a method of applying fasteners to cable end portions of a conveyor belt;

[0043] FIG. 33B-FIG. 38 is a cross-sectional view of a cable end portion and fasteners of the method of FIG. 33A

[0044] FIG. 39 is a perspective view of a fastener having multiple rows of longitudinally offset openings to receive set screws;

[0045] FIG. 40 is a cross-sectional view taken along line 40-40 of FIG. 39 showing set screws passing through openings in communication with blind holes of the fasteners;

[0046] FIG. 41 is a plan view of a two-stage conveyor belt joint assembled using two sets of longitudinally offset fastener assemblies;

[0047] FIG. 42 is an enlarged view of the area indicated by the dashed box in FIG. 41 ; and

[0048] FIG. 43 is a view similar to FIG. 42 , with the fastener assemblies removed to show the staggered ends of the cable end portions;

[0049] FIG. 44 is a perspective view of another fastener assembly showing an upstream cable fastener and a downstream cable fastener and an intermediate link having upper and lower link members connected by a ring of fastener members located at opposite ends of the link that secure the upper and lower link members of the link to the upstream and downstream fasteners;

[0050] FIG. 45 is a side view of the upstream cable fastener of FIG. 44 showing a narrow neck portion at an outer side end of the fastener and an adjacent enlarged head portion;

[0051] FIG. 46 is a bottom perspective view of the upper link member showing raised arcuate alignment protrusions extending around a central opening and raised alignment ridges extending radially from the central opening between the arcuate alignment protrusions;

[0052] FIG. 47 is a bottom view of the upper link member of FIG. 46 showing an upper end pocket portion of the upper link member configured to receive a head portion of the upstream cable fastener and a head portion of the downstream cable fastener;

[0053] FIG. 48 is a perspective view of a fastener assembly of FIG. 44 ​is a top perspective view of a lower connector member of a connector showing a central alignment recess extending around a central opening and an alignment recess extending radially from the central opening to receive a raised arcuate alignment protrusion and a raised alignment ridge of an upper connector member, respectively;

[0054] FIG. 49 is FIG. 48 is a top view of a lower connector member showing a lower end pocket portion of the lower connector member configured to receive a head portion of an upstream fastener and a head portion of a downstream fastener;

[0055] FIG. 50 is a cross-sectional view taken along line 50-50 in FIG. 44 is a cross-sectional view taken along line 50-50 in

[0056] FIG. 51 is a cross-sectional view similar to FIG. 50 is a cross-sectional view similar to

[0057] FIG. 52 is a cross-sectional view similar to FIG. 51 is a cross-sectional view similar to

[0058] FIG. 53 to FIG. 56 is a series of cross-sectional views showing a method of connecting cable end portions of a cable conveyor belt using the fastener assembly of FIG. 44 is a cross-sectional view taken along line 50-50 in FIG. 53 is a cross-sectional view taken along line 50-50 in

[0059] FIG. 54 is a view similar to FIG. 53 is a view similar to

[0060] FIG. 55 is a view similar to FIG. 54 is a view similar to

[0061] FIG. 56 is a view similar to FIG. 55The view shows the ring of the connector advancing to the end annular flange portion of the connector to keep the upper and lower connector components fixed to the head portions of the upstream fastener and the head portions of the downstream fastener during the operation of the conveyor belt.

[0062] FIG. 57 It is along FIG. 44 The cross-sectional view taken by line 57-57 shows the head portion of the cable fastener in the recessed portion of the lower connector component;

[0063] FIG. 58 yes FIG. 44 A side view of the connector assembly, showing an upstream cable fastener pivoting upward from the central horizontal axis of the connector and a downstream cable fastener pivoting downward.

[0064] FIG. 59 yes FIG. 58 A top view of the fastener assembly shows an upstream cable fastener that pivots laterally outward to extend laterally at an angle relative to the central longitudinal axis of the fastener assembly, and a downstream cable fastener that pivots laterally outward in the opposite direction away from the central longitudinal axis; and

[0065] FIG. 60 It is along FIG. 58 The cross-sectional view taken by line 60-60 shows the head portion of the upstream cable fastener and the head portion of the downstream cable fastener tilting within the recessed portion of the lower connector member due to the lateral tilting orientation of the upstream and downstream cable fasteners. Detailed Implementation

[0066] refer to FIG. 1 The diagram shows a connector 10 that mechanically connects to the ends 12, 14 of a heavy-duty cable conveyor belt 16 driven in a downstream longitudinal direction 17 to transport objects (e.g., aggregates). The ends 12, 14 include cable end portions 18, 20 exposed by removing a portion of the body 22 of the conveyor belt 16. FIG. 1 The diagram shows connector 10, in which filler 19 has been removed (see Figure 10). FIG. 3 For example, cured polyurethane, to clearly show the components of joint 10. FIG. 3 The image shows a filler 19, which provides an upper surface 23 for supporting the conveyed material and a lower surface 21 for contacting the pulley.

[0067] The joint 10 includes fastener assemblies 30, each of which connects a pair of aligned cable end portions 18, 20. The aligned pairs of cable end portions 18, 20 can each be opposite end portions of a single cable or can be end portions of different cables embedded in the belt 16. The filler 19 embeds the fastener assemblies 30 therein and can help retain the fastener assemblies 30 secured to the cable end portions 18, 20.

[0068] The fastener assemblies 30 include upstream cable fasteners 32 connected to respective upstream cable end portions 18, downstream cable fasteners 34 connected to respective downstream cable end portions 20, and intermediate connectors 35 connecting the upstream and downstream fasteners 32, 34. The upstream and downstream cable fasteners 32, 34 have locking members, such as set screws 36, that secure the upstream and downstream cable fasteners 32, 34 to the cable end portions 18, 20.

[0069] As shown in FIG. 2 , the upstream cable fasteners 32 include adjacent upstream cable fasteners 40, 42, the downstream cable fasteners 34 include adjacent downstream cable fasteners 44, 46, and the connectors 35 include intermediate connectors 50, 52. The upstream cable fastener 42 will be discussed in greater detail below, but it should be understood that the other upstream cable fasteners 32 (including the upstream cable fasteners 40, 42) and the downstream cable fasteners 34 (including the downstream cable fasteners 44, 46) will have the same or similar structure.

[0070] During installation of the joint 10, the upstream and downstream cable fasteners 32, 34 can be secured one at a time to respective upstream and downstream cable end portions 18, 20 by inserting the cable end portions 18, 20 into the blind holes 82 (see FIG. 3 ) of the fasteners 32, 34 and advancing the fasteners 32, 34 along the respective cable end portions 18, 20 to a desired longitudinal position. The upstream cable fasteners 32 are positioned on the cable end portions 18 so that the upstream cable fasteners 32 are laterally aligned on the conveyor belt end 12. Likewise, the downstream cable fasteners 34 are positioned on the cable end portions 20 so that the downstream cable fasteners 34 are laterally aligned on the conveyor belt end 14. For example and with reference to FIG. 2 , the inner side faces 160 (see FIG. 4Positioned on the transverse axis 39, the upstream cable fasteners 40, 42 are aligned transversely. By positioning the inner side faces 160 of the downstream cable fasteners 44, 46 on the transverse axis 41, the downstream cable fasteners 44, 46 are aligned transversely. Aligning the upstream cable fasteners 32 transversely on the cable end portion 18 and aligning the downstream cable fasteners 34 transversely on the cable end portion 20 limits uneven force application to the joint 10 during operation of the conveyor belt 16.

[0071] To align the upstream cable fasteners 32 and the downstream cable fasteners 34 on the cable end portions 18, 20, the installer can use a guide, such as an angle iron. Specifically, the installer first positions one leg of the angle iron to extend transversely across the cable end portion 18 and generally perpendicular to the cable end portion 18 and spaced apart from the fasteners 32 in which the cable end portion 18 is received. The installer then advances each of the upstream cable fasteners 32 along the cable end portion 18 until the inner side face 160 (see FIG. 4) of each of the upstream cable fasteners 32 abuts the angle iron. The inner side face 160 is closest to the upstream belt end 12. The installer then tightens the set screws 36 of the upstream cable fasteners 32 to secure the fasteners 32 to the cable end 18. The set screws 36 can be tightened by first tightening one of the set screws 36 farthest from the distal head portion 104 or closest to the inner side face 160 of each fastener 32 (e.g., set screw 36D in FIG. 4), tightening each of the other set screws (e.g., set screws 36A-36C) in the respective row (e.g., row 70 in FIG. 4) of set screws 36, and then performing similar operations on the set screws 36 in the other rows 72, 74 (see FIG. 4) of set screws 36. FIG. 4 ) of set screws 36. The installer then repeats the process for each of the other rows 72, 74 of set screws 36 until all of the upstream cable fasteners 32 are secured to the cable end portion 18. Next, the installer positions the angle iron on the downstream cable end portion 20 in the same manner and performs a similar process for each of the downstream cable fasteners 34. The upstream cable fasteners 32 and the downstream cable fasteners 34 can then be connected by the intermediate connector 35. FIG. 4 FIG. 6A

[0072] The process is repeated until all of the upstream cable fasteners 32 are secured to the cable end portion 18. Next, the installer positions the angle iron on the downstream cable end portion 20 in the same manner and performs a similar process for each of the downstream cable fasteners 34. The upstream cable fasteners 32 and the downstream cable fasteners 34 can then be connected by the intermediate connector 35.

[0073] Referring to FIG. 1, FIG. 2 the upstream cable end portion 18 includes cable end portions 18A, 18B, 18C and the downstream cable end portion 20 includes cable end portions 20A, 20B, 20C. In FIG. 2 ​​With reference to FIG. 1, a cable end portion 18C associated with fastener assembly 30 has been removed to illustrate an exposed length 49 of each cable end portion 18A, 18B, 18C that is trimmed of surrounding rubber and protrudes from an end face 62 of end 12 of conveyor belt 16 prior to being inserted into fastener 32. Likewise, cable end portions 20A, 20B, 20C protrude from an end face 64 of end 14 of conveyor belt 16. Each pair of cable end portions 18A, 20A, etc. can be opposite end portions of a single cable or end portions of different cables.

[0074] As shown in FIG. 2, fastener 42 has a body 80 with a hole (e.g., blind hole 82) and a tubular wall 84 extending therearound. Fastener 42 has multiple rows 70, 72, 74 of aligned set screws 36, with row 70 including set screws 36A-36D. Tubular wall 84 has multiple rows of threaded openings 86 that receive set screws 36A-36D and allow set screws 36A-36D to be driven into engagement with a set length 90 of cable end portion 18A received in blind hole 82. Body 80 can be made of a durable, high-strength material, such as steel. Example materials include 4140 pre-hardened steel and tempered 17-4 PH stainless steel. FIG. 3 FIG. 6A As shown in FIG. 2, fastener 42 has a body 80 with a hole (e.g., blind hole 82) and a tubular wall 84 extending therearound. Fastener 42 has multiple rows 70, 72, 74 of aligned set screws 36, with row 70 including set screws 36A-36D. Tubular wall 84 has multiple rows of threaded openings 86 that receive set screws 36A-36D and allow set screws 36A-36D to be driven into engagement with a set length 90 of cable end portion 18A received in blind hole 82. Body 80 can be made of a durable, high-strength material, such as steel. Example materials include 4140 pre-hardened steel and tempered 17-4 PH stainless steel.

[0075] As shown in FIG. 3, connector 52 has recessed pockets 100, 102 that receive distal annular head portions 104, 106 of fasteners 42, 46. Connector 52 has an upper connector member 110 and a lower connector member 112 that are secured together by an attachment member 114 (e.g., a bolt or screw). In one embodiment, attachment member 114 is an internal hex screw 116. Internal hex screw 116 has an enlarged head portion 118 that is received in a chamfered opening 115 of upper connector member 110 and a threaded shank portion 120 that engages an aligned threaded hole 122 of lower connector member 112. Upper and lower connector members 110, 112 can be made of a durable, high-strength material, such as steel. Example materials include 4140 pre-hardened steel and tempered 17-4 PH stainless steel. Internal hex screw 116 can be made of a high-strength alloy. FIG. 3 Once joint 10 is installed, tensile loads on cable end portions 18A, 20A cause head portions 104, 106 to abut against stop surfaces 130, 132 of connector 52. The engaged head portions 104, 106 and stop surfaces 130, 132 prevent fasteners 42, 46 from being pulled out of connector 52, thereby maintaining the mechanical connection between cable end portions 18A, 20A by fastener assembly 30.

[0076]

[0077] ​​Each cable of the conveyor belt 16 can be an assembly of a wire bundle, such as a 7-wire bundle containing 19 cables per bundle. The cables of the cable end portion 18 are held in fixed relation to the fastener 42 by the set screws 36 of the fastener 42, and form a fixed length 90 of the cable end portion 18A in the blind hole 82, as shown in FIG. 3 Referring to FIG. 4 , the set screws 36A-36D each have a tapered front end portion 131 that extends into the blind hole 82 to engage the wire bundle of the cable end portion 18A and disrupt the cables to wedge into the cable end portion 18A (e.g., between individual cables). Referring to FIG. 6A , the tapered front end portion 131 also exerts a compression force on the cables that cooperates with the compression forces exerted by the set screws 36 of the other rows 72, 74 to form local tight compression portions of the cables at and between the set screws 36. The cable portions of the cable end portion 18A intermediate the set screws 36 are subjected to less compression. These less compressed cable portions provide a wider portion of the cable end portion 18A that contacts the set screws 36 intermediate the longitudinally spaced set screws 36, which can further prevent the cable end portion 18A from being pulled out of the fastener 42.

[0078] With continued reference to FIG. 4 , the blind hole 82 of the fastener 42 has an outer section 150 of its overall length where the set screws 36 of the multiple rows 70, 72, 74 engage the cable end portion 18A. The length of the blind hole 82 is designed to extend a longitudinal distance 154 beyond the outermost set screw (e.g., set screw 36A) of the multiple rows 70, 72, 74. In this way, the distal end portion 152 of the cable end portion 18A can extend this distance 154 beyond the outermost set screw before the distal end 156 of the cable end portion 18A engages an end face 158 of the blind hole 82. This distance 154 accommodates some variation in the length of the cable end portion 18A during installation of the upstream cable fastener 32 and the downstream cable fastener 34. For example, for a shorter upstream cable end portion 18, the portion 152 of the cable can not extend all the way to the end face 158 of the blind hole 82.

[0079] In FIG. 4In particular, the cable end portion 18A is shown extending linearly straight out of the inner side entrance opening 194 of the blind hole 82, for example as the joint 10 travels between the rollers of an associated conveyor belt system. The fastener 42 has an inner side spacing portion 170 that spaces the inner side end face 160 of the fastener tubular wall 84 longitudinally inward of the innermost set screw 36, by a longitudinal distance 182, from the innermost set screw (e.g., set screw 36D) of the plurality of rows 70, 72, 74. The inner side spacing portion 170 of the fastener 42 provides a stress relief portion 180 of the cable end portion 18A in the blind hole 82. While the cable portions engaged by the set screws 36 are fixed against movement, the cable portions in the stress relief portion 180 of the cable end portion 18A can move relative to one another to relieve stress in the cable of the cable end portion 18A that can be generated by repeated flexing or bending of the cable end portion 18A, for example as they travel around the conveyor belt pulleys. Thus, the stress relief portion 180 of each cable end portion 18A can improve the durability of the joint 10.

[0080] Referring again to FIG. 4 , the tubular wall 84 of the fastener 42 has an inner surface 190 that extends around the blind hole 82, the inner surface 190 having a tapered surface portion 192 and a cylindrical surface portion 204. The tapered surface portion 192 flares outward as the inner surface 190 extends in the inner side direction toward the inner side entrance opening 194 of the blind hole 82. The tapered surface portion 192 provides a greater clearance for the movement of the cable end portion 18A in the blind hole 82 as the joint 10 travels around the pulleys of the conveyor belt system. The tapered surface portion 192 also includes a proximal end beveled arcuate surface portion 196 that extends around the inner side entrance opening 194 of the blind hole 82 to provide additional clearance to accommodate movement of the cable end portion 18A. The cable end portion 18A bends during the grooving and movement of the joint 10 around the conveyor belt pulleys, so the clearance provided by the tapered surface portion 192 reduces stress concentrations in the cable end portion 18A.

[0081] The fastener body 80 is sized according to the cable end portion 18A to be received in the blind hole 82. The size includes the inner diameter 204A of the cylindrical surface portion 204. The inner diameter 204A is sized to be larger than the diameter or cord size of the cable end portion 18A. For example, if the diameter of the cable end portion 18A is 8.1 mm to 9.0 mm, then the inner diameter 204A is 9.8 mm; if the diameter of the cable end portion 18A is 7.1 mm to 8.0 mm, then the inner diameter 204A is 8.8 mm; and if the diameter of the cable end portion 18A is 6.1 mm to 7.0 mm, then the inner diameter 204A is 7.8 mm.

[0082] AsFIG. 4 and FIG. 6A As shown, an annular space 200 exists between the cable end portion 18A and the tapered surface portion 192. As the fitting 10 travels around the sheave, the most proximal portion 210 of the cable end portion 18A in the entry opening region of the fastener 42 can bend in a direction 212 to accommodate the travel of the fitting 10 in the curved path around the sheave. As shown, FIG. 5 As a result of the bending of the cable portion 210 in the direction 212, the upper portion of the gap 200 increases, while the lower portion of the gap 200 decreases, as compared to that shown in FIG. 4 The bending of the stress relief portion 180 of the cable end portion 18A is limited by the contact of the stress relief portion 180 with the tapered surface portion 192, including the end beveled surface portion 196. By allowing the controlled movement of the portion 210 of the cable end portion 18A, the fastener 42 avoids the stress relief portion 180 bending with a radius that is less than the bending radius that the stress relief portion 180 can withstand, which limits stress concentration in the cable end portion 18A and improves the durability of the fitting 10.

[0083] Referring to FIG. 6A The body 80 of the fastener 42 can have a polygonal cross-sectional configuration, such as the generally hexagonal cross-section shown, with the outer surface 230 including wider flat surfaces 232, 234, 236 and narrower flat surfaces 238, 240, 242. The narrow flat surfaces 238, 240, 242 have multiple rows of threaded openings 86 formed therein to receive the multiple rows 70, 72, 74 of set screws 36. As a result of the presence of the set screws 36, the fastener 40, 42 each has a radial dimension 243 measured from the center of the blind bore 82 to the tail drive end 137 of each set screw 36 that is greater than a radial dimension 245 measured from the center of the blind bore 82 to each of the wider flat side surfaces 232, 234, 236.

[0084] The configuration of the body 80 of the fastener 42 balances competing objectives. First, the fastener 42 has a length 211 (see FIG. 4 as short as possible to facilitate the travel of the fitting 10 around the sheave while minimizing the deflection or bending of the cable end portion 18A by the fastener 42 as the fitting 10 travels around the sheave. Second, the body 80 of the fastener 42 is thicker at the longitudinal portions 213, 215, 217 between the threaded openings 86 of the multiple rows 70, 72, 74 (see FIG. 6B) has sufficient material to withstand stresses in the material of the body 80 caused by the compression of the cable end portion 18A in the blind hole 82 by the set screw 36 and the prevention of pullout of the cable end portion 18A during operation of the conveyor belt 16. More specifically, the thicker portions 213, 215, 217 have a thickness 219 between the blind hole 82 and the narrow flat surfaces 238, 240, 242 of the portions 213, 215, 217 that is sized to provide sufficient strength to resist stresses in the material of the body 80 during operation of the conveyor belt 16. The thickness 219 is greater than a thickness 221 between the blind hole 82 and the wide flat surfaces 232, 234, 236 of the thinner portions 223, 225, 227 of the body 80 of the fastener 42. Because there are no threaded set screw openings in the narrow portions 223, 225, 227, the body 80 requires less material at the narrow portions 223, 225, 227 to withstand stresses in the material of the body 80 at the narrow portions 223, 225, 227. In this manner, the greater thickness 219 at the set screw threaded openings 86 and extending longitudinally along the rows 70, 72, 74 strengthens the body 80 and improves the durability of the fastener 42 while allowing the length 211 of the fastener 42 to be minimized. In one embodiment, the fastener 42 has a length 211 of 2.588 inches, the threaded openings 86 have an inner diameter of 0.25 inches, the thickness 219 is 0.135 inches, and the thickness 221 is 0.069 inches.

[0085] During installation, after fastener 42 is secured to cable end portion 18B, fastener 40 is positioned on cable end portion 18B with an orientation that is 60° clockwise relative to the orientation of adjacent fastener 42. As a result of fastener 40 being rotated 60° clockwise relative to fastener 42, row 70A of set screws 36 of fastener 40, which includes set screw 36F, is adjacent to wide flat surface 234 of fastener 42. As a result of surface 234 of fastener 42 being adjacent to row 70A of set screws 36 of fastener 40, surface 234 has an associated smaller dimension 245, thus fastener 42 occupies less space near row 70A of set screws 36 of fastener 40, which provides a gap between fastener 42 and row 70A of set screws 36 of fastener 40, while also providing a compact arrangement between adjacent fasteners 40 and 42. Similarly, row 74 of set screws 36 of fastener 42, which includes set screw 36G, is adjacent to wide flat surface 232A of fastener 40. In this manner, wide flat surfaces 232, 234, 236 of fasteners 40, 42 provide a gap for set screws 36 of adjacent fasteners 40, 42, and allow fasteners 42, 40 to be attached to cable end portions 18A, 18B in a tight arrangement or compact arrangement. Furthermore, fastener 42 can be moved in directions 73, 75 by bending cable end portion 18A in order to provide clearance for an installer to connect a driving tool to set screws 36 of rows 70A, 72A of fastener 40.

[0086] Reference is made to FIG. 7 , fastener assembly 30 includes rotational connections 250, 252 between fastener 42, connector 52, and fastener 46. Rotational connections 250, 252 allow fasteners to be turned in opposite rotational directions 256, 258 relative to central axis 260 of fastener assembly 30 during assembly of joint 10. The ability of fasteners 42, 46 to turn relative to connector 52 relieves stress in cable end portions 18, 20 that can be caused by tightening set screws 36 onto cable end portions 18, 20. For example, as set screws 36 are tightened, a tapered front end portion 131 of one of set screws 36 of fastener 42 can advance into a recessed space or depression between wire bundles of cable end portion 18A, thereby pushing the cables apart and can exert a torque on cable end portion 18A.

[0087] Furthermore, rotational connections 250, 252 allow fasteners 42, 46 to be secured to connector 52 in any rotational orientation of fasteners 42, 46 about central axis 260. This makes it easier to connect fasteners 42, 46 to intermediate connector 52, for example, by allowing fasteners 42, 46 to be turned to different rotational positions relative to intermediate connector 52, which can be caused by tightening set screws 36.

[0088] With reference to FIG. 8 , the fastener 42 has an annular outer portion 270 adjacent the distal annular head portion 104 and having a base portion 272 and a neck portion 274 connecting the base portion 272 to the head portion 104. The head portion 104 has a stop surface 276 that engages the stop surface 130 (see FIG. 3 ) of the connector 52 and prevents the head portion 104 from being pulled out of the connector 52. The stop surface 276 includes annular radial shoulder surfaces 280, 282, 284 that face in the inboard direction and that increase in diameter from the innermost surface 280 to the outermost surface 284. The head portion 104 has annular axial side surfaces 281, 283, 285 that extend axially from the respective annular radial surfaces 280, 282, 284 to form a stepped profile of the head portion 104.

[0089] With reference to FIG. 16 , the stop surface 130 of the connector 52 includes annular stop shoulder surfaces 330, 332, 334 that decrease in diameter from the outermost surface 330 to the innermost surface 334. The annular radial shoulder surfaces 280, 282, 284 of the fastener head portion 104 and the annular stop surfaces 330, 332, 334 of the connector 52 are flat and in facing relationship to prevent the head portion 104 from wedging the upper and lower connector members 110, 112 apart when the joint 10 is tensioned and the fastener 42 is pushed in the inboard direction 312 (see FIG. 9 ) during operation of the conveyor belt 16.

[0090] FIG. 7 The rotational connection 250 of the head portion 104 is provided by the annular radial surfaces 280, 282, 284 (see FIG. 8 ) and the axial side surfaces 281, 283, 285 of the head portion 104 that are sized and configured to allow them to slide and rotate relative to the respective adjacent surfaces of the annular stop surface portions 330, 332, 334 (see FIG. 16 ) and the annular axial side surfaces 287, 289, 291 of the connector 52 before the head portion 104 is pulled tightly against the connector 52 by tension in the cable end portions 18A, 20A. In other words, during installation of the joint 10, the head portion 104 has the above-described annular surfaces that can rotate relative to the respective, adjacent or facing annular surfaces of the connector 52 when the head portion 104 is received in the connector 52 and before tension is applied to the cable end portions 18A, 20A.

[0091] With reference to FIG. 8, the size and configuration of the connector pockets 100, 102 and the head portion 104, base portion 272, and neck portion 274 of the fasteners 42, 46 are designed to allow controlled oscillation of the fasteners 42 relative to the connectors 52 in the directions 370, 372 (see FIG. 9 ) as the joint 10 travels around the pulley.

[0092] The head portion 104, neck portion 274, and base portion 272 have annular cross sections that allow the fasteners 42 to pivot or oscillate relative to the connectors 52 in any rotational orientation of the fasteners 42 relative to the connectors 52.

[0093] As shown in FIG. 8 and FIG. 11 , the head portion 104 includes a tapered guide surface 290 and a small end flat 292 to provide clearance for pivoting or oscillating in the connector pocket 100. The neck portion 274 has a concave annular neck surface portion 294 that decreases in outer diameter as the neck portion 274 extends outwardly away from the base portion 272 and inwardly from the head portion 104, reaching a minimum outer diameter at about midway between the base portion 272 and the head portion 104. The concave neck surface portion 294 is configured to oscillate in the directions 370, 372 about an annular convex necked surface portion 310 of the connector 52.

[0094] Referring to FIG. 9 , the head portion 104 of the fastener 42 is shown received in the connector pocket 100 that is captured between the upper and lower connector members 110, 112 that are secured together. The connector 52 has a connector end entrance opening 300 that leads to the connector pocket 100 and receives the neck portion 274 of the fastener 42. The connector 52 has a narrowed or necked annular portion 302 formed by mating semicircular rim portions 304, 306 (see FIG. 12 ) of the upper and lower connector members 110, 112. The rim portions 304, 306 each include one-half of a convex necked surface portion 310. During operation of the conveyor belt 16, the concave neck surface portion 294 of the fastener 42 is pressed tightly against the convex necked surface portion 310 of the connector 52 in the direction 312 due to tension in the joint 10. In this manner, some of the axial load caused by tension in the conveyor belt 16 is transmitted between the fastener 42 and the connector 52 by the tightly engaged concave neck surface portion 294 and convex necked surface portion 310.

[0095] As previously mentioned, the stop surface 130 of the connector 52 includes annular stop shoulder surfaces 330, 332, 334, as shown in FIG. 16The annular stop shoulder surfaces 330, 332, 334 are formed by semicircular stop surface portions 336, 338, 340 of the upper connector member 110 that are radially coplanar with corresponding semicircular stop surface portions 342, 344, 346 of the lower connector member 112 when the upper and lower connector members 110, 112 are assembled. The diameter of the annular stop shoulder surfaces 330, 332, 334 decreases progressively from the radially outermost annular stop shoulder surface 330 to the radially innermost annular stop shoulder surface 334. Likewise, the convexly necked surface portion 310 of the connector 52 is formed by semicircular convexly necked surface portions 350, 352 of the rim portions 304, 306 of the upper and lower connector members 110, 112.

[0096] Returning to FIG. 9 The blind bore 82 of the fastener 42 has a central axis 360 that is shown to be coaxial with the central axis 260 of the fastener assembly 30. As shown, the tapered guide surface 290 of the fastener 42 has a spacing or gap 362 from the interior flat end face 364 of the pocket 100 when the cable end portions 18A, 20A are in tension during belt operation and the fastener surface portion 294 is engaged with the connector surface portion 310. The head portion 104, neck portion 274, and pocket 100 are configured to allow the fastener 42 to swing in directions 370, 372 and move the central axis 360 to positions 380, 382 that are at angles 374, 376 from the initial position of the central axis 360. In one embodiment, the head portion 104, neck portion 274, and pocket 100 limit each of the angles 374, 376 to a maximum of about 2°.

[0097] In the above described tensioned configuration, the tapered guide surface 290 has an upper portion 390 that has a varying distance 392 from the end face 364 and a lower portion 394 that has a similar varying distance 396 from the end face 364. Due to the conical configuration of the fastener guide surface 290, the distances 392, 396 increase progressively in a radially outward direction from the center of the end face 364. Thus, when the fastener 42 swings in the direction 372, the distance 396 decreases while the distance 392 increases. Conversely, when the fastener 42 swings in the direction 370, the distance 396 increases while the distance 392 decreases.

[0098] FIG. 9The fastener 42 is shown in a typical tension configuration when the joint 10 is under a tension load, with the center axis 360 of the blind hole 82 coaxial with the center axis 260 of the fastener assembly 30. In the typical configuration, the entirety (or 360 degrees) of each of the annular radial surfaces 280, 282, 284 of the fastener head portion 104 is in flush engagement with the entirety of the corresponding annular stop surface portion 330, 332, 334 of the link pocket 100. As the fastener 42 is swung from the initial position in either direction 370 or 372, the entirety of each of the annular radial surfaces 280, 282, 284 is reduced in engagement with the corresponding annular stop surface portion 330, 332, 334. The ability of the fastener 42 to swing in the directions 370, 372 allows the fastener assembly 30 to release tension in the fastener assembly 30 as the joint 10 travels around the pulley.

[0099] With respect to FIG. 10 , the fastener 42 is shown with the set screw 36 advanced into the blind hole 82. With respect to the set screw 36D, the set screw 36D is a pointed set screw having a frustoconical guide side surface 400 that applies a lateral wedging force to the cables of the cable bundle, and a guide surface 402 for advancing into the gap between the cable bundles of the cable. The set screw 36 is turned using a driver (e.g., an impact driver with a drill bit) that engages the rotational drive structure of the set screw 36, e.g., the hex drive hole 37 (see FIG. 8 ). As the set screw 36 is tightened, the set screw 36 advances radially inward in the direction 404 into the blind hole 82. Once the joint 10 is installed, the filler 19 (see FIG. 3 ) (e.g., polyurethane) prevents the set screw 36 from loosening.

[0100] With respect to FIG. 12 , the assembled intermediate link 52 is shown disconnected from the fasteners 42, 46. The interior hex screw 116 holds the link 110, 112 together, while the filler 19 prevents the interior hex screw 116 from loosening. The link 110, 112 prevents the fasteners 42, 46 from separating (see FIG. 3 ) and from being under tension during operation of the conveyor belt 16. Since the tension of the conveyor belt 16 will act primarily in the longitudinal direction, and that tension is borne by the fasteners 42, 46 and the link 110, 112, but not the interior hex screw 116, the load borne by the interior hex screw 116 is much less. The interior hex screw 116 exerts sufficient compressive force on the link members 110, 112 to keep the head portions 104, 106 of the fasteners 42, 46 captured within the pockets 100, 102 of the link 52.

[0101] Turning to FIG. 13, the connector 52 is shown in exploded view with the hex head cap screws 116 removed from the counterbore openings 115 and the holes 122 of the connector members 110 and 112, respectively. With reference to FIG. 13 and FIG. 14 It can be seen that the semicircular rim portion 304 of the upper connector member 110 extends along the concave recessed opening 410 in one end 412 of the upper connector member 110, and the upper connector member 110 has a corresponding semicircular rim portion 414 that extends along a concave recessed opening 416 at the other end 418 of the upper connector member 110. The upper connector member 110 has a lower surface 420 in which are formed recessed pocket portions 422, 424 that communicate with the corresponding openings 410, 416. Likewise, as shown in FIG. 15 the lower connector member 112 has openings 430 and 434 along which semicircular rim portions 306 and 436 extend at ends 432 and 438, respectively. The lower connector member 110 has recessed pocket portions 440, 442 that communicate with the corresponding openings 430, 434.

[0102] With reference to FIG. 14 and FIG. 15 the recessed pocket portions 424, 442 have semicircular stop surface portions 340A, 338A, 336A and 342A, 344A, 346A that can be identical to the stop surface portions of the previously described recessed pocket portions 422, 440. In this manner, the semicircular stop surface portions of the recessed pocket portion 422 and the recessed pocket portion 440 cooperate to form the previously described annular stop shoulder surfaces 330, 332, 334 that engage the head portion 104 of the fastener 42 and prevent it from being pulled out (see FIG. 16 ), while the stop surface portions 340A, 338A, 336A and 342A, 344A, 346A of the recessed pocket portions 424, 442 cooperate to engage the head portion 106 of the fastener 46 and prevent it from being pulled out. Moreover, the identical arrangement of stop surface portions of the recessed pocket portions 422, 440 and 424, 442 allows the connector 52 to be provided with either the recessed pocket portions 422, 440 or the recessed pocket portions 424, 442 that receive either of the fastener head portions 104, 106, thereby simplifying installation. In other words, the connector 50 (see FIG. 2 ) can be oriented so that either end 50A, 50B of the connector 50 can be attached to one of the upstream fasteners 32, while the opposite end 50A, 50B can be attached to the corresponding downstream fastener 34.

[0103] With reference back to FIG. 1In one embodiment, the joint 10 includes an additional body, such as a plate or sheet 35A, which the installer positions over the cable end portions 18, 20 prior to applying the filler 19 to reduce the amount of filler 19 used to form the joint 10. The sheet 35A can be made of, for example, rubber or polyurethane. The sheet 35A has an opening 37 to allow the filler 19 to flow through the sheet 35A and form a joint of the filler 19 and the sheet 35A to secure the sheet 35A to the filler 19.

[0104] Turning to FIG. 17 , an alternative fastener 500 is provided that can be used to repair more minor belt damage, such as a hole 502 (see FIG. 20B ), in a conveyor belt 506 having cables 508 rather than spending time and effort installing a complete joint, such as the joint 10 described above, between cut and prepared belt ends. The fastener 500 includes a body 510 having a tubular sidewall 512 and end portions 520, 522. The tubular sidewall 512 extends around blind holes 514, 516 of the body 510. The holes 514, 516 are sized to receive cable end portions advanced into the holes 514, 516 in directions 515, 517. The fastener 500 has set screws 548 for securing the cable end portions in the holes 514, 516.

[0105] The fastener 500 has a row 546 of set screws 548 that are received in a corresponding row of threaded openings 550 in the sidewall 512 along the length of the body 510 (see FIG. 19 ). The set screws 548 include a first set 552 of set screws 548 for engaging a first cable end portion in the hole 514 and a second set 554 of set screws 548 for engaging a cable end portion received in the hole 516.

[0106] With regard to FIG. 18 , the body 510 can have a polygonal cross-sectional configuration, such as the generally hexagonal cross-sectional configuration shown, similar to the body 80 of the fastener 42 described above. The body 510 has narrow flat surfaces 530, 532, 534 and wide flat surfaces 536, 538, 540. The hexagonal shape of the body 510 of the fastener 500 allows the fastener 500 to be installed side-by-side on the cables of a belt without the fasteners 500 contacting each other.

[0107] The set screws 548 of the row 546 protrude from the narrow flat surface 530 of the body 510. The set screws 548 each have a frustoconical side surface 560 and a flat guide surface 562. The set screws 548 grip the cable end portions by breaking the strands of the cable end portions and clamping the cable end portions against the inner surfaces 567, 569 (see FIG. 19The cable end portions are secured in the holes 514, 516 by the lower surface portions 564, 565 of the fastener 500.

[0108] With reference to FIG. 19 , the fastener 500 has a middle portion 570 with stops 572, 574 to limit movement of the cable end portions into the holes 514, 516 in the directions 515, 517. In one embodiment, the middle portion 570 includes a wall 580 and the stops 572, 574 include annular surfaces 582, 584 of the wall 580, which can be conical or flat, to contact the free ends of the cable end portions received in the holes 514, 516.

[0109] Next, reference will be made to FIG. 20A to FIG. 27 which illustrates a method 581 for repairing a damaged portion 601 (e.g., a hole 502) of a conveyor belt 506. The method 581 involves installing a patch 605 (see FIG. 27 ) that covers the hole 502 and facilitates continued use of the conveyor belt 506 without having to replace the conveyor belt 506 or cut and splice the conveyor belt 506 (e.g., using the splice 10 previously described). The patch 605 blocks the hole 502, protects the cables 508, and prevents the hole 502 from enlarging.

[0110] The conveyor belt 506 has an upper cover layer 504 and a lower cover layer 505 (see FIG. 25 ) with a body 600 therebetween. The upper cover layer 504, the body 600, and the lower cover layer 505 can be made of different types of rubber. For example, the upper cover layer 504 can be made of a first rubber with a higher abrasion resistance, the body 600 can be made of a second rubber that facilitates vulcanization and splicing of the cables 612A-612C, 660, 662, and the lower cover layer 505 can be made of a third rubber with a low rolling resistance. The hole 502 can extend through the upper cover layer 504, the body 600, and the lower cover layer 505. The hole 502 can be due to a puncture in the conveyor belt 506 caused by, for example, a sharp object (e.g., a piece of aggregate) falling onto the conveyor belt 506 or multiple pieces of aggregate repeatedly falling onto the same location of the conveyor belt. The hole 502 includes damaged cable end portions 602, 604 of the cables 508 on approximately either side of the hole 502. The cable wires of the damaged cable end portions 602, 604 can become entangled with the cable wires of adjacent cables and form a tangled cable bundle in the hole 502 and protrude from the hole 502.

[0111] Reference is made to FIG. 21Method 581 includes, at step 603, trimming or removing portions of the cover 504 and the body 600 from the damaged portion 601 to form an enlarged opening 610 over the original opening or hole 502. The damaged cable end portions 602, 604 are cut to provide trimmed cable end portions 612, 614 having ends 616, 618 that are laterally aligned with other trimmed cable end portions 612, 614 on the conveyor belt 506.

[0112] Next, method 581 includes, at step 585, attaching fasteners 620, 622 to the trimmed cable end portions 612, 614, as shown in FIG. 22 and FIG. 23 Fasteners 620, 622 are each similar to fasteners 500 of FIG. 17 With specific reference to FIG. 23 , fastener 620 includes fasteners 620A, 620B, 620C and fastener 622 includes fasteners 622A, 622B, 622C.

[0113] At step 587, method 581 also includes securing an intermediate connection cable 624 to fasteners 620, 622. Connection cable 624 includes connection cable 624A, 624B, 624C, as shown in FIG. 23 The assembly of fasteners 620, 622 and connection cable 624 connect the trimmed cable end portions 612, 614 and form a patch support 630 that extends through the enlarged opening 610. The patch support 630 provides structure that can be attached to a filler 680 (see FIG. 27 ) as part of filling the enlarged opening 610. Connection cable 624 can be the same as or different from cable 508.

[0114] With respect to FIG. 24 , fasteners 620A, 622A are shown with their holes 514, 516 receiving cable end portions 612A, 614A and end portions 650, 652 of connection cable 624A. Set screws 548 have been tightened to secure fasteners 620A, 622A to cable end portions 612A, 614A and connection cable 624A.

[0115] With respect to FIG. 25 , conveyor belt 506 shows cables 660, 662 embedded in undamaged portions 635 of body 600. Cable end portions 612A, 612B, 612C extend through a portion of enlarged opening 610 and are secured to fasteners 620A, 620B, 620C.

[0116] Patch support 630 is then installed in opening 610, as shown in FIG. 26The method 581 optionally includes, at step 589, removing material of the cover layer 504 around the opening 610 to form a recessed portion 670 in the cover layer 504 that extends around the opening 610. The recessed portion 670 increases the surface area of the cover layer 504 that engages the filler 680 while allowing the filler 680 to be flush with the uppermost surface 671 of the overlying cover layer 504.

[0117] At step 591, the method 81 includes applying the filler 680 to cover the recessed portion 670 and fill the enlarged opening 610. The filler 680 can include, for example, polyurethane. During the filling operation, a backing (e.g., a strong adhesive tape or a plastic material) can be applied to the underside of the conveyor belt 506 to prevent the filler 680 from flowing out of the opening 610. Once the filler 680 solidifies, the filler 680 has an upper surface 682 that is flush or level with the uppermost surface 671 of the conveyor belt 506. The upper surface 682 of the filler 680 can support the material being conveyed. In addition, the filler 680 plugs the enlarged opening 610, preventing objects from becoming stuck on the conveyor belt 506 or otherwise further damaging the conveyor belt 506.

[0118] Reference is made to FIG. 28A to FIG. 32 , a method 701 is provided for securing cable end portions 710, 712, 714, 716 (710, 712, 714, 716) FIG. 32 ) of fasteners 700, 702, 704, 706 (700, 702, 704, 706) FIG. 28B ) to an end of a conveyor belt. Reference is made to FIG. 29 The fastener 700 includes a body 730 having a blind hole 732 that receives the cable end portion 710. The fastener body 730 has narrow flat surfaces 782, 772, 792 similar to the narrow flat surfaces 238, 240, 242 (see FIG. 6A ) of the fastener 42 described above. The fastener 700 has multiple rows 760, 762, 764 of set screws 733 that are threadably engaged with a corresponding multiple rows of threaded set screw openings 735 of the body 730. The set screws 733 each have a front end portion 750 having a flat guide surface 752 and a frustoconical side surface 754. The trailing end portions of the set screws 733 of the row 760 protrude from the narrow flat surface 782 of the body 730.

[0119] As FIG. 28BAs shown, the cable end portions 710, 712, 714, 716 each have a predetermined pitch 722 between the centers of adjacent cable end portions 710, 712, 714, 716. The pitch 722 provides a lateral spacing 724 between the cable end portions 710, 712, 714, 716. The pitch 722 can be, for example, 14.5 mm, and the diameter of the cable end portions 710, 712, 714, 716 can be 7.6 mm.

[0120] The method 701 includes positioning 703 the fastener 700 on the cable end portion 710 so that the cable end portion 710 is received in the hole 732. The positioning 703 step includes setting the longitudinal position of the fastener 700 along the cable end portion 710 by advancing the fastener 700 inwardly or proximally along the cable end portion 710 until the inward or proximal end of the fastener 700 abuts a stop (e.g., an angle iron having leg portions extending transversely or orthogonally across the cable end portions 710-716). The positioning 703 step also includes setting the rotational position of the fastener 700 by turning the fastener 700 to orient one of the narrow flat surfaces (e.g., the narrow flat surface 782 of the body 730 shown) to extend vertically toward the adjacent cable end portion 712.

[0121] The method 701 includes driving 705 one or both of the set screws 733 to set the longitudinal position and rotational position of the fastener 700 on the cable end portion 710. The driving 705 of one or both of the set screws 733 includes causing the installer to move or advance one or both of the set screws 733 into an engaged position, e.g., by tightening the set screws 733, to engage and temporarily secure the fastener 700 to the cable end portion 710 so that the installer can review the longitudinal position and rotational orientation of the fastener 700 on the cable end portion 710. If desired, the installer can loosen one or both of the set screws 733 and reposition the fastener 700.

[0122] Once the installer is satisfied with the position of the fastener 700 on the cable end portion 710, the method 701 includes securing 707 the fastener 700 to the cable end portion 710. The securing 707 step includes causing the installer to drive the remaining set screws 733 of the fastener 700 to their final advanced or installed position to secure the fastener 700 to the cable end portion 710. Driving or moving the set screws 733 to their final advanced position causes the set screws 733 to engage and secure the fastener 700 to the cable end portion 710. FIG. 29 from the initial configuration to the FIG. 30the initial engagement position of the set screw 733. The installer can use a drive tool (e.g., an Allen wrench or power tool) to move the remaining set screws 733 into engagement position to engage and tighten the set screws 733. In one approach, the drive tool is a power tool with a clutch to prevent the drive tool from applying more than a predetermined torque to the set screws 733.

[0123] For example, the installer tightens the set screws 733 of the row 762 before tightening the set screws 733 of the row 760 and the set screws 733 of the row 764. To do so, the installer can move or bend the cable end portion 712 upward in the direction 800 or downward in the direction 802 to provide sufficient clearance to connect a drive tool to the set screws 733 of the row 762. In this manner, the set screws 733 of the row 762 can be accessed and tightened without interference from the fasteners on the cable end portion 712, making it easier to tighten the set screws 733 of the row 762.

[0124] Referring to FIG. 30 , the installer pushes the set screws 733 of the multiple rows 760, 762, 764 radially inward into the blind hole 732 toward the cable end portion 710 until the trailing end surface 780 of each set screw 733 is flush with or slightly above the associated narrow flat surface 782, 772, 792 of the fastener body 730. Each set screw 733 of the multiple rows 760, 762, 764 deforms the cables of the cable end portion 710 in a similar manner, including pressing the cable end portion 710 against the annular inner surface 740 of the blind hole 732 and separating and spreading the cables of the cable end portion 710 by the front end portion 750 driven therebetween.

[0125] The method 701 includes positioning 709 a next fastener 702 on the cable end portion 712 once the fastener 700 is secured to the cable end portion 710 (see FIG. 30 ). The step 709 includes the installer positioning the next fastener 702 on the cable end portion 712 in a similar manner as the fastener 700, as described above with respect to the fastener 700. FIG. 31The body 730 of the fastener 702 has a wide flat surface 757 that is spaced apart from the set screws 733 of the row 762 of the fastener 700 by a gap 759. The step 709 includes rotationally orienting the fastener 702 so that the wide flat surface 757 of the fastener 702 extends parallel to the narrow flat surface of the fastener 700 associated with the set screws 733 of the row 762 of the fastener 700. Because the set screws 733 of the row 762 of the fastener 700 have been moved to their final advanced position prior to positioning the fastener 702 on the cable end portion 712, the installer is able to secure the fastener 700 to the cable end portion 710 despite the close proximity of the wide flat surface 757 of the fastener 702 to the set screws 733 of the row 762 of the fastener 700.

[0126] The installer sets the longitudinal position of the fastener 702 on the cable end portion 712 and the rotational orientation of the fastener 702 in a similar manner as discussed above with respect to the fastener 700. At step 711, the installer moves one or both of the set screws 733 of the fastener 702 to an initial engagement position to temporarily secure the fastener 702 to the cable end portion 712, confirms the positioning of the fastener 702, and then moves the remaining set screws 733 to their final, more radially advanced position at step 713. As the installer uses a driving tool to drive the set screws 733 of the row 762 to their final advanced position, the installer can move the cable end portion 714 in the direction 800 or the direction 802 to provide clearance for the driving tool. Moreover, because the multiple rows 760, 764 of the fastener 702 are positioned above and below the row 762 of the fastener 700, the set screws 733 of the multiple rows 760, 764 of the fastener 702 are accessible without interference from the fastener 700. Thus, although the installer can choose to move the cable end portion 714 in the direction 800 or the direction 802 to drive the set screws 733 of the multiple rows 760, 764 to their final advanced position, they are not necessarily required to do so.

[0127] Once the installer secures the fastener 702 to the cable end portion 712, the installer secures the fasteners 704 and 706 to the cable end portions 714, 716, respectively, in a similar manner as discussed above with respect to the fasteners 700, 702. With respect to the fastener 704, the installer sets the longitudinal position of the fastener 704 on the cable end portion 714 and the rotational orientation of the fastener 704 in a similar manner as discussed above with respect to the fastener 700. At step 715, the installer moves one or both of the set screws 733 of the fastener 704 to an initial engagement position to temporarily secure the fastener 704 to the cable end portion 714, confirms the positioning of the fastener 704, and then moves the remaining set screws 733 to their final, more radially advanced position at step 717. As the installer uses a driving tool to drive the set screws 733 of the row 762 of the fastener 704 to their final advanced position, the installer can move the cable end portion 716 in the direction 800 or the direction 802 to provide clearance for the driving tool. Moreover, because the multiple rows 760, 764 of the fastener 702 are positioned above and below the row 762 of the fastener 700, the set screws 733 of the multiple rows 760, 764 of the fastener 702 are accessible without interference from the fastener 700. Thus, although the installer can choose to move the cable end portion 716 in the direction 800 or the direction 802 to drive the set screws 733 of the multiple rows 760, 764 to their final advanced position, they are not necessarily required to do so. FIG. 32 , the fasteners 700-706 are shown secured to the cable end portions 710-716. The installer installs the fasteners 700-706 on the conveyor belt end portions 710-714 in the order shown in FIGS. 28-31, respectively, and in the order shown in FIGS. 32-35, respectively. The installation process proceeds in a right-to-left manner from the perspective of FIGS. 28-31 and in a left-to-right manner from the perspective of FIGS. 32-35. FIG. 32 , the fasteners 700-706 are shown secured to the cable end portions 710-716. The installer installs the fasteners 700-706 on the conveyor belt end portions 710-714 in the order shown in FIGS. 28-31, respectively, and in the order shown in FIGS. 32-35, respectively. The installation process proceeds in a right-to-left manner from the perspective of FIGS. 28-31 and in a left-to-right manner from the perspective of FIGS. 32-35. FIG. 32The orientation of the fasteners 700-706 is shown rotated 180 degrees to attach the fasteners in a left-to-right manner such that one of the narrow surfaces of the fasteners to be mounted on the cable end portion 716 faces toward the adjacent cable end portion 714.

[0128] Turning to FIG. 33A-FIG. 38 , a method 801 is provided for securing fasteners 810, 812, 814, 816 to cable end portions 820, 822, 824, 826 having a pitch 829 of, for example, 14 mm, which is slightly less than FIG. 28B the pitch 722 of the cable 700. The fasteners 810-816, including set screws 840, can be similar or identical in size and configuration to the fasteners 700-706, including set screws 733, discussed above. The method 801 is similar to the method 701 discussed above and includes steps 803, 805, 811 similar to the steps 703, 705, 711 discussed above.

[0129] One difference between the method 801 and the method 701 is that the set screws 840 of the row 844 of fasteners 810-816 are driven radially inwardly deeper than the set screws 733 of the row 762 of fasteners 700-706 (see FIG. 29 ) to more fully compress the cable end portions 820-826 in the fasteners 810-816 before the set screws of the multiple rows 842, 846 are driven to their final advanced or installed position. As a result of the set screws 840 of the row 844 being driven radially inwardly deeper, the fasteners 810-816 can be positioned on the cable end portions 820-826 without spacing between the fasteners 810-816. Specifically, the fasteners 810-816 can be positioned with the narrow flat surfaces 870 (see FIG. 35 ) of each fastener 810-816 abutting or in close proximity to the wide flat surfaces 900 (see FIG. 36 ) of the adjacent fasteners 810-816. Thus, the method 801 facilitates a more compact or tight arrangement of the fasteners 810-816 on the cable end portions 820-826 compared to the method 701.

[0130] The method 801 includes the installer positioning 803 the fastener 810 on the cable end portion 820 as shown in FIG. 34 . The positioning 803 step includes setting the longitudinal position of the fastener 810 along the cable end portion 820 using a stop (e.g., an angle iron extending through the cable end portions 820-826) and setting the rotational orientation of the fastener 810 by orienting the narrow flat surface 870 of the fastener 810 to extend vertically.

[0131] The installer then drives one or both of the set screws 840 of the row 844 of fasteners 810 to their initial engagement position 805 to temporarily secure the fasteners 810 to the cable end portion 820. The installer confirms or reviews the longitudinal position and rotational orientation of the fasteners 810.

[0132] The method 801 includes securing 807 the fasteners 810 to the cable end portion 820. The securing 807 step includes having the installer drive the set screws 840 of the row 844 to their final, more radially advanced position, wherein the trailing end surface 860 of each set screw 840 is recessed or inset from the narrow flat surface 870 of the fastener 810, as shown. FIG. 35

[0133] By moving the set screws 840 of the row 844 radially inward to their final advanced and recessed position, the leading end portion 880 of each set screw 840 of the row 844 is driven further into the blind hole 832 of the fastener 810 than the set screw 733 to more fully compress the cable end portion 820 within the blind hole 832 of the fastener 810. More specifically, driving or tightening the set screws 840 of the row 844 downward such that the leading end portion 880 of each set screw 840 pushes the cable end portion 820 against the annular inner surface 834 of the blind hole 832. The leading end portion 880 of the set screw 840 has a frustoconical surface 890 and a leading flat surface 892 for displacing the cable end portion 820 within the blind hole 832. The installer tightens the set screws 840 of the row 844 until the trailing end surface 860 of each set screw 840 is located radially inward of the narrow flat surface 870, and further driving and advancement of the set screws 840 is prevented by the compressed cable end portion 820.

[0134] ​Once the installer moves the set screw 840 of the row 844 to its final advanced position, the securing 807 step includes the installer moving the set screws 840 of the other rows 910, 912 radially inward to their final advanced positions by tightening the remaining set screws 840. Because the set screw 840 of the row 844 is moved to its radially further final advanced position, the cable end portion 820 is fully compressed to its maximum extent, so the final advanced position of the set screws 840 of the rows 910, 912 is radially outward of the final advanced position of the set screw 840 of the row 844. Once the set screws 840 compress the cable end portion 820 against the annular inner surface 834 and seal the air gap between the cables of the cable end portion 820, the set screws 840 fully compress the cable end portion 820. Compressing the cable end portion 820 beyond the fully compressed configuration would involve significantly higher torque applied to the set screws 840 because further compression would involve deforming the cables of the cable end portion 820 and creating stresses in the material of the body 830. Because of the significant increase in torque involved in attempting to compress the cable end portion 820 beyond the fully compressed configuration, once the cable end portion 820 has been fully compressed by the set screw 840 of the row 844, the clutch of the power drive tool used to drive the set screws 840 can disengage the drill bit of the tool from the power source, which makes it easy for the installer to recognize that the set screw 840 of the row 844 has fully compressed the cable end portion 820.

[0135] After the set screw 840 of the row 844 has fully compressed the cable end portion 820 in the blind hole 832, the set screws 840 of the rows 910, 912 generally cannot further compress the cable end portion 820. Therefore, the installer moves the set screws 840 of the rows 910, 912 to their final advanced positions by tightening the set screws 840 of the rows 910, 912 until the radial inward movement of the set screws 840 is substantially limited or stopped by the compressed cable end portion 820 in the blind hole 832. The set screws 840 of the rows 910, 912 have trailing end surfaces 940, 942 that project outward from the radially outer side of the narrow flat surfaces 930, 932 of the fastener 810, as shown in FIG. 35

[0136] With regard to FIG. 36 ​Next, the method 801 includes positioning 809 the fastener 812 on the cable end portion 822 by the installer. Positioning the fastener 812 on the cable end portion 822 includes rotationally orienting the fastener 812 on the cable end portion 822 such that the wide flat surface 900 of the fastener 812 is immediately adjacent to or abutting the narrow flat surface 870 of the fastener 810. The wide flat surface 900 and the narrow flat surface 870 can extend parallel to each other. In embodiments having a smaller pitch between the cable end portions, the fasteners 810, 812 can be in contact, while in embodiments having a larger pitch between the cable end portions, there can be a narrower spacing between the fasteners 810, 812, for example similar to the fasteners 700-706 for the cable end portions 710-716. The spacing between the bodies 830 of the fasteners 810, 812 can be narrower than the spacing of the fasteners 700, 702 due to the set screws 840 of the row 844 recessed into the threaded openings 871 of the row 844. Positioning the fastener 812 on the cable end portion 822 also includes setting the longitudinal position of the fastener 812 along the cable end portion 822 by advancing the fastener 812 in a proximal or inboard direction until it abuts a stop (e.g., an angle iron extending transversely across the cable end portions 820-826).

[0137] At step 811, the installer moves one or both of the set screws 840 of the row 844 of the fastener 812 to its engaged position to temporarily secure the fastener 812 to the cable end portion 822. If the longitudinal position and rotational orientation of the fastener 812 on the cable end portion 822 is acceptable, the installer drives the set screws 840 of the row 844 to their final, more radially advanced position, and the set screws 840 of the rows 910, 912 to their final, more radially advanced positions, as shown at step 813. FIG. 37

[0138] The installer uses similar methods as discussed above with respect to the fasteners 810, 812 to sequentially apply the fasteners 814 and 816 to the cable end portions 824, 826 in a right-to-left manner. With respect to FIG. 38 , the fasteners 810-816 are shown secured to the cable end portions 820-824 with the fasteners 810-816 immediately adjacent to each other in a side-by-side arrangement.

[0139] Referring to FIG. 39 and FIG. 40 , a fastener 1000 is shown that is similar to the fasteners 32, 34 discussed above, so the differences will be highlighted below. The fastener 1000 includes a tubular body 1002 having narrow flat surfaces 1004, 1006, 1008 with rows 1010, 1012, 1009 (see​FIG. 40 Threaded set screw openings 1014 of the plurality of rows 1010, 1012, 1009 receive set screws 1012. Threaded set screw openings 1014 of the plurality of rows 1010, 1012, 1009 receive set screws 1012 of the plurality of rows 1010, 1012, 1009.

[0140] The plurality of rows 1010, 1012, 1009 of set screw openings 1014 are longitudinally offset from one another along a central longitudinal axis 1030 of fastener 1000. Set screw openings 1014 of row 1010 are longitudinally closer to a distal head portion 1015 of fastener 1000 than are corresponding set screw openings 1014 of rows 1012, 1009. Set screw openings 1014 of row 1009 are longitudinally farther from head portion 1015 than are corresponding set screw openings 1014 of rows 1010, 1012. Set screw openings 1014 of row 1012 are longitudinally intermediate corresponding set screw openings 1014 of rows 1010, 1009.

[0141] For example, set screw openings 1014A of row 1010 have central axes 1040 that are offset in the medial direction by an offset distance 1042 from central axes 1044 of corresponding set screw openings 1014B of row 1009 of set screw openings 1014. As a result of offset distance 1042, set screws 1012 received in set screw openings 1014A, 1014B will engage the cable end portion at different longitudinal locations along the cable end portion that is received in blind bore 1050 of fastener 1000. The longitudinally offset engagement between set screws 1012 in set screw openings 1014A, 1014B provides an alternating compression pattern of the cable of the cable end portion and can provide additional resistance to pull out of the cable end portion in blind bore 1050.

[0142] With respect to FIG. 41 , a two-stage joint 1100 is provided for connecting end portions 1102, 1104 of a conveyor belt 1106. Conveyor belt end portion 1102 includes cable end portions 1110, 1112 that are connected together by a first set 1120 of fastener assemblies 30 and a second set 1122 of fastener assemblies 3 discussed above with respect to FIG. 7 The first set 1120 of fastener assemblies 30 and the second set 1122 of fastener assemblies 30 connect to cable end portions 1110, 1112 such that the first set 1120 of fastener assemblies 30 and the second set 1122 of fastener assemblies 30 are longitudinally offset from one another along conveyor belt 1106.

[0143] The longitudinal offset between the fastener assemblies 30 of the first group 1120 and the fastener assemblies 30 of the second group 1122 allows the fastener assemblies 30 of the first group 1120 and the fastener assemblies 30 of the second group 1122 to travel around the pulley in different rotational positions. In this manner, tension pulses in the cable end portions 1110, 1112 (e.g., created by fastener assemblies 30 traveling onto or off of the pulley) are not applied to all of the cable end portions 1110, 1112 and their corresponding fastener assemblies 30 at the same time. For example, if the fastener assemblies 30 of the first group 1120 are traveling onto the pulley while the fastener assemblies 30 of the second group 1122 have not yet reached the pulley, the tension in the cable end portions 1110, 1112 connected by the fastener assemblies 30 of the second group 1122 can temporarily be lower than the tension in the cable end portions 1110, 1112 connected by the fastener assemblies 30 of the first group 1120. Thus, the two-stage joint 1100 facilitates that tension pulses created by the joint 1100 traveling onto or off of the pulley are not applied to all of the cable end portions 1110, 1112 and fastener assemblies 30 at the same time. Specifically, with the two-stage joint 1100, when the associated fastener assemblies 30 of the first group 1120 or the second group 1122 travel onto or off of the pulley, half of the cable end portions 1110, 1112 are subjected to a tension pulse, while the other half of the cable end portions 1110, 1112 will temporarily be subjected to a lower tension pulse due to the other associated group 1120, 1122 of fastener assemblies 30 being off of the pulley or already on the pulley.

[0144] With regard to FIG. 43 The cable end portions 1110 include shorter cable end portions 1111 and longer cable end portions 1113. Likewise, the cable end portions 1112 include shorter cable end portions 1115 and longer cable end portions 1117. Each shorter cable end portion 1111 of the conveyor belt end 1102 is connected to a corresponding one of the longer cable end portions 1117 of the conveyor belt end 1104 by one fastener assembly 30. Each longer cable end portion 1113 of the conveyor belt end 1102 is connected to a corresponding one of the shorter conveyor belt end portions 1115 of the conveyor belt end 1104 by one fastener assembly 30. There is a longitudinal gap 1119 between the cable end portions 1110, 1112 that is spanned by the fastener assemblies 30.

[0145] With reference to FIG. 42 Each fastener assembly 30 includes an upstream fastener 32 and a downstream fastener 34 connected to the cable end portions 1110, 1112, and a connector 35 connecting the upstream fastener 32 and the downstream fastener 34. The connector 35 is received in the longitudinal gap 1119 between the cable end portions 1110, 1112.

[0146] In one embodiment, there is a longitudinal spacing 1124 between the fastener assemblies 30 of the first group 1120 and the fastener assemblies 30 of the second group 1122 along the conveyor belt 1106, as shown. In another embodiment, there is no longitudinal spacing between the fastener assemblies 30 of the first group 1120 and the fastener assemblies 30 of the second group 1122 along the conveyor belt 1106, and the fastener assemblies 30 of the first group 1120 and the fastener assemblies 30 of the second group 1122 can overlap in the lateral direction. FIG. 43

[0147] A three-stage joint similar to the two-stage joint 1100 can be provided. The three-stage joint utilizes three groups of fastener assemblies 30 longitudinally offset along the conveyor belt 1106. The three-stage joint can further reduce the number of cable end portions 1110, 1112 and associated fastener assemblies that are simultaneously subjected to tension pulses as the three-stage joint travels onto or off of a roller. Specifically, when the associated group of fastener assemblies 30 travels onto or off of a pulley, one-third of the cable end portions 1110, 1112 will experience a tension pulse, while the remaining two groups of fastener assemblies 30 are either off of the pulley or already on the pulley. For example, the three-stage joint can be used for a conveyor belt having a 7000 N / mm breaking strength, 12.4 mm diameter steel cable, and a pitch between the centers of the steel cables of 19.5 mm. In another embodiment, the three-stage joint can be used for a conveyor belt having a 5000 N / mm breaking strength, 9.2 mm diameter steel cable, and a pitch between the centers of the steel cables of 15.9 mm.

[0148] FIG. 44 ​A fastener assembly 1200 is shown that is similar in many respects to the fastener assembly 30 discussed above and can be secured to cable end portions of a cable conveyor in a manner similar to the methods discussed above. The fastener assembly 1200 includes an upstream cable fastener 1202, a downstream cable fastener 1204, and an intermediate link 1206 that allows controlled movement, e.g., pivoting and / or rotating, of the upstream and downstream fasteners relative to the link 1206, e.g., as the steel cable conveyor 16 including the joint formed with the fastener assembly 1200 travels around a pulley. By allowing controlled relative movement of the upstream fastener 1202 and the downstream fastener 1204 to the link 1206, as the cable end portions move and bend to position the upstream fastener 1202 and the downstream fastener 1204, the cable end portions re-orient the upstream fastener 1202 and the downstream fastener 1204 relative to the link 1206 to effectively transfer tensile loads between the cable end portions while limiting peak stresses in the fastener assembly 1200. In other words, by allowing movement between the upstream fastener 1202 and the downstream fastener 1204 to the link 1206, the fasteners 1202, 1204 can change their orientation relative to the link 1206 (and vice versa) as the fasteners 1202, 1204 pass over a curved pulley surface and prevent an angular orientation of either cable end portion 1600, 1602 and the associated fasteners 1202, 1204. As the fasteners 1202, 1204 remain in linear alignment with the cable end portions 1600, 1602, the cable end portions 1600, 1602 exert tensile loads on the fasteners 1202, 1204 rather than bending moments. It has been found that bending moments on the fasteners 1202, 1204 create stress concentrations in the neck portion 1314 (see FIG. 45 ) of the fasteners 1202, 1204 and adversely affect the durability of the joint. The ability of the upstream fastener 1202 and the downstream fastener 1204 to move relative to the link 1206 (and vice versa) provides the fastener assembly 1200 with sufficient range of motion to pass over a pulley while maintaining the cable end portions 1600, 1602 exerting tensile loads on the fasteners 1202, 1204 rather than bending loads.

[0149] The upstream fastener 1202 and the downstream fastener 1204 each include a body 1207 having a polygonal cross-section including a wider flat surface 1208 and a narrower flat surface 1210. The narrower flat surface 1210 has a plurality of rows of threaded openings 1212 for receiving set screws. The body 1207 has a blind hole 1220 for receiving a cable end portion.

[0150] The connector 1206 has an upper connector member 1230, a lower connector member 1232, and a first attachment member, such as a threaded attachment member in the form of a screw 1234 connecting the upper connector member 1230 and the lower connector member 1232. The connector 1206 also includes a second attachment member and a third attachment member, such as loops 1240, 1242 that press fit onto end arcuate flange portions 1250, 1252, 1254, 1256 (see FIG. 46 and FIG. 48 ) of the upper connector member 1230 and the lower connector member 1232. The loops 1240, 1242 can be made of a durable, high-strength material, such as steel. Example materials include 4140 pre-hardened steel and tempered 17-4 PH stainless steel.

[0151] To splice the ends of a conveyor belt using the fastener assembly 1200, the cable end portions of the conveyor belt ends are inserted into the blind holes 1220 of the upstream fastener 1202 and the downstream fastener 1204, and the set screws are tightened to secure the cable end portions in the blind holes 1220. Next, the connector 1206 is assembled with the upstream fastener 1202 and the downstream fastener 1204 (as described further below). The fastener assembly 1200 is similarly connected to other cable end portions of the conveyor belt, and the fastener assembly 1200 is covered by the filler, as previously described.

[0152] Once the joint is installed, the conveyor belt is tensioned, which causes the cable end portions secured to the upstream fastener 1202 and the downstream fastener 1204 to exert tension in directions 1222, 1224. The tension acting in the directions 1222, 1224 brings the enlarged head portions 1270, 1280 (see FIG. 56 ) of the upstream fastener 1202 and the downstream fastener 1204 into close engagement with stop surfaces, such as the semi-annular, partially spherical surfaces 1294, 1294A (see FIG. 47 ) of the upper connector member 1230 and the semi-annular, partially spherical surfaces 1296, 1296A (see FIG. 49 ) of the lower connector member 1232. The screw 1234 and the loops 1240, 1242 of the connector 1206 prevent the upper and lower connector members 1230, 1232 from separating in directions 1260, 1262 transverse to the tension directions 1222, 1224, which can be caused by the cable end portions stretching under load forcing the upstream and downstream fasteners to separate in the directions 1222, 1224 and the engagement of the curved surfaces of the head portions 1270, 1280 being forcibly pulled against the spherical surfaces 1294, 1294A.

[0153] Reference is next made to FIG. 45The upstream cable fastener 1202 will be described, with the understanding that the downstream cable fastener 1204 has the same structure. The upstream cable fastener 1202 has a head portion 1270 that is sized to be received in an upstream connector pocket 1272 (see FIG. 50 ), formed by an upper end pocket portion 1274 (see FIG. 46 ) of the upper connector member 1230 and a lower end pocket portion 1276 (see FIG. 48 ) of the lower connector member 1232. Similarly, the downstream cable fastener 1204 has a head portion 1280 (see FIG. 53 ) that is sized to be received in a downstream connector pocket 1282 (see FIG. 54 ), formed by an upper end pocket portion 1284 (see FIG. 46 ) of the upper connector member 1230 and a lower end pocket portion 1286 (see FIG. 48 ) of the lower connector member 1232.

[0154] With continued reference to FIG. 45 , the head portion 1270 has a stop surface 1290 for preventing pullout of the head portion 1270 in the direction 1222 due to tension in the associated cable end portion. In one embodiment, the stop surface 1290 includes a partial spherical surface 1292 that rotatably and pivotally engages with partially annular, partial spherical shoulder surfaces 1294 (see FIG. 46 ) and 1296 (see FIG. 48 ) of the upper and lower connector members 1230 and 1232. The engaged partial spherical surface 1292 of the head portion 1270 and the partially annular, partial spherical surfaces 1294, 1296 of the upper and lower connector members 1230 and 1232 allow rotatable and pivotal movement of the head portion 1270 in the connector pocket 1272, including up / down (see FIG. 50 ) in the directions 1356, 1358 and lateral left / right (see FIG. 57 ) in the directions 1700, 1702, as well as movement in compound directions, such as in a lateral left up direction and a lateral right down direction. The engaged partial spherical surfaces 1292, 1294, 1296 act as a ball and socket connection, as described above, that also allows rotatable movement of the upstream cable fastener 1202 in the rotational directions 1265, 1267 (see FIG. 44 ). In this manner, the upstream cable fastener 1202 generally has a conical range of motion relative to the connector 1206 as the cable end portion secured to the upstream cable fastener 1202 moves and bends during operation of the associated conveyor belt. The downstream cable fastener 1204 has a similar conical range of motion relative to the connector 1206.

[0155] Referring FIG. 45 to FIG. 27, the head portion 1270 includes a cylindrical surface portion 1300, a tapered beveled portion 1302, and a transverse flat end face portion 1304. The cylindrical surface portion 1300 extends from the spherical surface portion 1292 to the tapered beveled portion 1302, which extends to the transverse flat end face portion 1304. The fastener 1202 has a base portion 1310 with an annular shoulder surface 1312 that tapers down to a narrow neck portion 1314 of the upstream cable fastener 1202. The neck portion 1314 has an annular neck surface portion 1316 that extends between the shoulder surface 1312 and the partially spherical surface 1292 of the enlarged head portion 1270.

[0156] As FIG. 46 to FIG. 49 shown, the upper and lower connector members 1230, 1232 have cooperating alignment portions 1451, 1453 that are configured to matingly engage one another to ensure proper alignment of the upper and lower connector members 1230, 1232. The alignment portion 1451 of the upper connector member 1230 includes a raised arcuate protrusion 1450 that extends around the upper opening 1400, and diametrically opposed raised ridges 1452, 1454 that extend radially from the opening 1400 and are located between the ends of the protrusion 1450, as shown in FIG. 46 and FIG. 47 The alignment portion 1453 of the lower connector member 1232 includes a recess 1460 that extends around the lower threaded opening 1420, and diametrically opposed channels 1462, 1464 that extend radially from the opening 1420 to interrupt the recess 1460 as they extend through the recess 1460, as shown in FIG. 48 and FIG. 49 When the upper and lower connector members 1230, 1232 are brought together around the fastener head portions 1270, 1280 (see FIG. 53 and FIG. 54 ), the protrusion 1450 engages in the recess 1460, and the ridges 1452, 1454 engage in the channels 1462, 1464.

[0157] Referring FIG. 50 to FIG. 27, the connector 1206 has an upper concave recessed opening 1332 formed by the upper connector member 1230 (see FIG. 46 ), and a lower concave recessed opening 1334 formed by the lower connector member 1232 (see FIG. 48) to form an entry opening 1330. When the fastener assembly 1200 is assembled with the upstream cable fastener 1202 adjustably connected to the connector 1206, the neck portion 1314 of the upstream cable fastener 1202 extends into the end entry opening 1330 to position the enlarged head portion 1270 of the upstream cable fastener 1202 in the connector end pocket 1272. The upper connector member 1230 and the lower connector member 1232 have necked down portions 1251, 1253 that are smaller in diameter than the varying diameter through the end pocket 1272 to narrow the entry opening 1330 and prevent the upstream fastener head portion 1270 from being pulled out of the end pocket 1272.

[0158] When the conveyor belt is tensioned, the upstream cable fastener 1202 is urged in the direction 1222 which brings the partially spherical surface 1292 of the head portion 1270 into close engagement with the semi-annular partially spherical surfaces 1294, 1296 of the upper and lower connector members 1230, 1232. The end arc flange portion 1250 of the upper connector member 1230 has an upper tapered collar inner surface 1350 and the end arc flange portion 1254 of the lower connector member 1232 has a lower tapered collar inner surface 1352. As shown in FIG. 50 and FIG. 51 the upper tapered collar inner surface 1350 is configured to engage the annular neck surface portion 1316 of the upstream cable fastener 1202 and limit pivoting of the fastener 1202 in the direction 1356. The upper tapered collar inner surface 1350 has a semi-truncated conical surface that flares outwardly or expands radially as the upper tapered collar inner surface 1350 extends in the outboard direction (e.g., direction 1222).

[0159] Conversely, as shown in FIG. 50 and FIG. 52 the lower tapered collar inner surface 1352 is configured to engage the annular neck surface portion 1316 of the upstream cable fastener 1202 and limit pivoting of the upstream cable fastener 1202 in the direction 1358. The lower tapered collar inner surface 1352 also has a semi-truncated conical surface that flares outwardly or expands radially as the lower tapered collar inner surface 1352 extends in the outboard direction (e.g., direction 1222).

[0160] In addition, the upper tapered collar inner surface 1350 and the lower tapered collar inner surface 1352 also cooperate to engage the annular neck surface portion 1316 of the upstream cable fastener 1202 and limit pivoting of the upstream cable fastener 1202 in the transverse or side-to-side directions 1700, 1702 (see FIG. 57). In this manner, the upper and lower conical collar inner surfaces 1350, 1352 define a conical range of motion for the fastener, and in the illustrated form, limit the fastener 1202 to a range of + / - 8° pivoted from a central position, as shown. FIG. 50 In other words, the fastener 1202 is able to pivot such that the central axis 1360 of the fastener 1202 is 0° in FIG. 50 , is pivoted 8° upward in FIG. 51 , and is pivoted 8° downward in FIG. 52 . Further, the ball and socket connection of the upstream fastener head portion 1270 and the upstream link pocket 1272 enables the upstream cable fastener 1202 to rotate about the central axis 1360. By providing a limited conical range of motion, stresses in the fastener 1202 are kept within an acceptable range during operation of the conveyor belt, while allowing the fastener 1202 to move relative to the link 1206, and also avoiding failure of the fastener assembly 1200 (e.g., while traveling over a pulley).

[0161] Returning to FIG. 50 , the end arc flange portions 1250, 1254 have a semi-annular configuration, and include semi-annular outer channel portions 1380, 1382 and semi-annular ring retaining lip portions 1384, 1386 to form the end annular flange 1369, the annular outer channel 1371 of the end flange 1369, and the annular lip 1373 of the channel 1371 when the upper and lower link members 1230, 1232 are secured together by the screw fasteners 1234. The ring 1240 is press fit onto the end flange 1369 in a direction 1390 to be received in its annular channel 1371. The press fit of the ring 1240 involves elastically deforming and expanding the ring 1240 radially to temporarily increase the inner diameter of the ring 1240 to fit over the semi-circular ring retaining lip 1373. Once the ring 1240 is advanced past the semi-circular ring retaining lip 1373, the ring 1240 snaps into the semi-circular channel 1371 and returns to a less radially expanded configuration in the channel 1371. In another embodiment, the press fit of the ring 1240 onto the end flange 1369 involves elastically deforming the end flange 1369 in addition to or instead of deforming the ring 1240.

[0162] When the ring 1240 is received in the outer channel 1371, the ring 1240 is securely and tightly elastically engaged with the annular outer surfaces 1381, 1383 of the channel 1371. In addition, the annular ring keeps the lip 1373 from moving the ring 1240 in the direction 1392 away from the annular end flange 1369, away from the connector 1206 and toward the fastener 1202. In this way, the ring 1240 encircles the end arc flange portions 1250, 1254 and prevents their separation. In this way, the ring 1240 resists the camming force exerted by the upstream fastener head portion 1270 on the annular portion spherical surface 1279 formed by the semi-annular portion spherical surfaces 1294, 1296 that urges the upper and lower connector member 1230, 1232 apart in the directions 1260, 1262 when the upstream fastener is subjected to a tensile load in the direction 1222 by the associated cable end portion. Thus, the ring 1240 ensures that the separation force is not borne entirely by the screw fastener 1234. The ring 1242 likewise encircles the end arc flange portions 1252, 1256 of the other end of the connector 1206 and prevents their separation.

[0163] Referring to FIG. 46 and FIG. 50 the upper connector member 1230 has an upper opening 1400 with a chamfered upper portion 1402 dimensioned to receive a head portion 1404 of the screw 1234. The head portion 1404 abuts a stop surface 1406 of the chamfered upper portion 1402 and a shank portion 1408 of the screw 1234 extends into a lower hole portion 1410 of the upper opening 1400. Referring to FIG. 48 and FIG. 50 the lower connector member 1230 has a lower threaded opening 1420 aligned with the lower hole portion 1410 and having a thread 1422 configured to engage a thread 1424 of the shank portion 1408 of the screw 1234.

[0164] Referring to FIG. 53 to FIG. 56 a method of connecting cable end portions 1600, 1602 using the fastener assembly 1200 is provided. With reference to FIG. 53 the method includes first securing the upstream fastener 1202 to the cable end portion 1600 and the downstream fastener 1204 to the cable end portion 1602 by positioning the cable end portions 1600, 1602 in the blind holes 1220 of the upstream and downstream fasteners 1202, 1204. Next, the set screws 1604, 1606 are advanced into the threaded openings 1212 and tightened to secure the cable end portions 1600, 1602 in the blind holes 1202.

[0165] In one method, the set screws 1604A, 1604B, 1604C are tightened with a first torque and the set screw 1604D is tightened with a reduced torque. It has been found that the reduced torque of one or more of the inboard set screws 1604, such as set screw 1604D, provides a transition portion 1610 in the cable of cable end portion 1600 that is aligned with or located in the area of set screw 1604D. The transition portion 1610 provides a portion of the cable with reduced stress applied by set screw 1604D adjacent to a higher stress portion 1611 of the cable that is applied by the adjacent outboard set screw 1604C, and a more inboard lower stress portion 1612 of the cable has no set screw applying force to the cable. The cable of cable end portion 1600 has a higher stress in the higher stress portion 1611 because the cable is deformed by set screw 1604C and is pressed against the inner surface 1221 of the blind hole 1220 with a greater force than the cable of cable end portion 1600 in the area of set screw 1604D. The cable of cable end portion 1600 has a lower stress in the lower stress portion 1612 because the cable is not clamped by a set screw in the lower stress portion 1612 and can move relative to one another.

[0166] The transition portion 1610 provides a gradual transition of the stress of the cable of cable end portion 1600 between the higher stress portion 1611 and the lower stress portion 1612. It has been found that the reduced torque applied to set screw 1604D and the associated gradual transition of the stress of the cable of the cable provided by transition portion 1610 increases the durability of the connection between the upstream cable fastener 1202 and cable end portion 1600. The durability of the connection between the upstream cable fastener 1202 and cable end portion 1600 is improved because the gradual transition of the stress of the cable of cable end portion 1600 provided by transition portion 1610 reduces the stress steps that can occur in the cable of cable end portion 1600 when the cable moves relative to one another during operation of the conveyor belt. For example, set screws 1604A, 1604B, 1606C are tightened with a torque of 30 ft-lb and set screw 1604D is tightened with a torque of 15 ft-lb. The set screws 1606 of downstream cable fastener 1204 are tightened in a similar manner to set screws 1604 of upstream fastener 1204, with inboard set screw 1606D being tightened with a reduced torque compared to set screws 1606A, 1606B, 1606C.

[0167] In another method, the set screws 1604, 1606 have two or more inner set screws 1604, 1606 that are reduced in torque. For example, set screws 1604A, 1604B can be tightened with 100% of the maximum torque, set screws 1604C can be tightened with 75% of the maximum torque, and set screws 1604D can be tightened with 50% of the maximum torque. Although a row of set screws 1604A-1604D is discussed, other rows of set screws of the upstream cable fastener 1202 can be tightened in a manner similar to that discussed for the row of set screws 1604. FIG. 53

[0168] Once the upstream fastener 1202 and the downstream fastener 1204 are secured to the cable end portions 1600, 1602, the intermediate connector 1206 is assembled. The upper and lower connector members 1230, 1232 of the intermediate connector 1206 are positioned so that the upper pocket portions 1274, 1284 of the upper connector member 1230 and the lower pocket portions 1286 of the lower connector member 1232 are aligned with the head portions 1270, 1280 of the upstream and downstream fasteners 1202, 1204. As shown in FIG. 54 the upper and lower connector members 1230, 1232 are brought together to form connector pockets 1272, 1282 that surround the head portions 1270, 1280 of the upstream and downstream cable fasteners 1202, 1204.

[0169] Next, the installer pushes the shank portion 1408 of the screw 1234 into the upper opening 1400 of the upper connector member 1230, threadably engages the shank portion 1408 with the lower threaded opening 1420 of the lower connector member 1232, and tightens the screw 1234 so that the head portion 1404 of the screw 1234 is seated in the chamfered opening 1402 of the upper connector member 1230 and secures the upper and lower connector members 1230, 1232 together, as shown in FIG. 55

[0170] As shown in FIG. 55 and FIG. 56 the rings 1240, 1242 are advanced in directions 1390, 1392 toward the intermediate connector 1206 and onto the end annular flanges 1369, 1369A formed by the end arcuate flange portions 1250, 1254 and 1252, 1256 of the upper and lower connector members 1230, 1232. In another method, the rings 1240, 1242 are pressed onto the end arcuate flange portions 1250, 1254 and 1252, 1256 and then the screw 1234 is attached to the upper and lower connector members 1230, 1232.

[0171] ​​The connector pockets 1272, 1282 of the connector 1206, and the head portions 1270, 1280 of the upstream and downstream fasteners 1202, 1204 are configured to accommodate non-linear tension application in the associated conveyor belt. For example, as shown in FIG. 58 and FIG. 59 the upstream and downstream fasteners 1202, 1204 are vertically tilted or offset with respect to the connector 1206. More specifically, the upstream cable fastener 1202 is pivoted upwardly such that the central axis 1360 of the upstream fastener 1402 is at a positive angle 1704 with respect to the horizontal central axis 1706 of the connector 1206. Conversely, the downstream fastener 1404 is pivoted downwardly such that the central axis 1708 of the downstream fastener 1404 is at a negative angle 1710 with respect to the horizontal central axis 1706. The positive angle 1704 can be +8°, while the negative angle 1710 can be -8°. The relative pivotal motion of the upstream and downstream fasteners 1202, 1204, and the connector 1206 can also include pivoting of the connector 1206.

[0172] Referring to FIG. 59 , the upstream and downstream fasteners 1202, 1204 are also laterally tilted or offset, and are pivoted in the lateral direction such that the central axes 1360 and 1708 are at angles 1712, 1714 with respect to the central longitudinal axis 1720 of the connector 1206. If the connector 1206 is directed to rotate from the original installation orientation during operation of the conveyor belt (e.g., turned clockwise or counterclockwise when viewed in FIG. 58 and FIG. 59 , the fasteners 1202, 1204 can still move with respect to the connector 1206. For example, the fastener 1202 can still pivot in the directions 1356, 1358, rotate in the directions 1265, 1267, or a combination of both. Likewise, if one or both of the fasteners 1202, 1204 are directed to rotate from the original installation orientation during operation of the conveyor belt, the fasteners 1202, 1204 and the connector 1206 can still move with respect to each other.

[0173] With regard to FIG. 60 , the upstream and downstream connector pockets 1272, 1282 of the connector 1206 each include an annular partial spherical surface 1279 formed by the partial spherical surfaces 1294, 1296 (of the upstream connector pocket 1272) or the partial spherical surfaces 1294A, 1296A (of the downstream connector pocket 1282) (see FIG. 50 ). The annular partial spherical surfaces 1279 of the connector 1206 allow the partial spherical surfaces 1292, 1292A of the fastener head portions 1270, 1280 to pivot to the angles 1712, 1714 with respect to the central axis 1720 of the connector 1406.

[0174] The use of singular terms, such as "a," "an," "one," and "the" is intended to encompass both the singular and the plural, unless the context clearly dictates otherwise. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms. The phrase "at least one" is to be interpreted as having the same meaning as the phrase "one or more." For example, the phrase "at least one of A and B" is intended to encompass A, B, or both A and B.

[0175] While particular embodiments of the present application have been shown and described, it will be understood that many changes and modifications will occur to those skilled in the art, and it is intended to encompass just such changes and modifications within the scope of the appended claims.

Claims

1. A fastener assembly for connecting a first cable end portion and a second cable end portion of a cable conveyor belt, the fastener assembly comprising: A first cable fastener has a first head portion and a first plurality of locking members for securing the first cable fastener to the first cable end portion; The second cable fastener has a second head portion and a plurality of locking members for securing the second cable fastener to the end of the second cable. as well as A connector having a first recess and a second recess, the first recess being sized to receive a first head portion and the second recess being sized to receive a second head portion, the first recess and the second recess, as well as the first head portion and the second head portion, being configured to allow the first cable fastener and the second cable fastener to move relative to the connector during operation of the cable conveyor belt.

2. The fastener assembly of claim 1, wherein the connector comprises an upper connector member and a lower connector member, the upper connector member and the lower connector member having recess portions that mate to form the first recess and the second recess; and An attachment member for securing the upper connector member and the lower connector member around the first head portion and the second head portion.

3. The fastener assembly of claim 2, wherein the attachment member comprises a threaded attachment member.

4. The fastener assembly of claim 2, wherein the attachment member comprises a threaded attachment member and a retaining ring.

5. The fastener assembly of claim 1, wherein the connector comprises: An upper connector component and a lower connector component are assembled around a first head portion of the first cable fastener and a second head portion of the second cable fastener. Each of the upper connector component and the lower connector component has a pair of end arcuate flange portions that cooperate to form end annular flanges at opposite ends of the connector. as well as A retaining ring is configured to extend around the end annular flange of the connector and prevent separation of the upper connector member and the lower connector member.

6. The fastener assembly of claim 5, wherein the upper connector member and the lower connector member include openings aligned with the upper connector member and the lower connector member assembled around a first head portion of the first cable fastener and a second head portion of the second cable fastener; and A threaded attachment member extends through an aligned opening and prevents separation of the upper and lower connector members.

7. The fastener assembly of claim 1, wherein the connector recess and the fastener head portion include a partially spherical surface portion configured to engage with each other to allow the first cable fastener and the second cable fastener to move relative to the connector.

8. The fastener assembly of claim 7, wherein the first cable fastener includes a first neck portion and the second cable fastener includes a second neck portion; in, The connector includes an opening leading to a first recess and an opening to a second recess for receiving a first neck portion of the first cable fastener and a second neck portion of the second cable fastener. and The connector includes a neck portion extending around the opening, the neck portion being configured to contact the first neck portion and the second neck portion and to restrict displacement of the first cable fastener and the second cable fastener relative to the connector.

9. The fastener assembly of claim 1, wherein the first cable fastener includes a first neck portion having an annular neck surface, and the second cable fastener includes a second neck portion having an annular neck surface; in, The connector includes an opening leading to a first recess and an opening to a second recess for receiving a first neck portion of the first cable fastener and a second neck portion of the second cable fastener. and The connector includes an annular stop surface extending around the opening, the annular stop surface being configured to contact the neck surface and restrict displacement of the first cable fastener and the second cable fastener relative to the connector.

10. The fastener assembly of claim 1, wherein the first cable fastener includes a hole for receiving a first cable end portion, and the second cable fastener includes a hole for receiving a second cable end portion; and in, The first plurality of locking members and the second plurality of locking members include locking screws for engaging a first cable end portion received in a hole in the first cable fastener and a second cable end portion received in a hole in the second cable fastener.

11. A cable fastener for connecting the cable end portion of a conveyor belt, the fastener comprising: The main body has holes for receiving the end portion of the cable; The inner surface of the body extending around the hole; The main body has multiple narrow outer surfaces; The body has multiple wide outer surfaces that alternate with the narrow outer surfaces around the body; The narrow outer surface has multiple rows of threaded openings, which extend to the inner surface; A fixing screw is disposed in the threaded opening and operable to secure the end portion of the cable to the hole; The thicker portion of the body, which extends between the inner surface and the narrow outer surface, serves to reinforce the body adjacent to the multi-row threaded through opening; as well as The thinner portion of the body, extending between the inner surface and the wide outer surface, allows the cable fastener to be compactly positioned adjacent to the cable fastener secured to the end portion of the adjacent cable attached to the conveyor belt.

12. The cable fastener of claim 11, wherein each fixing screw includes a front end portion that contacts the cable end in the hole, and a tail end portion opposite to the front end portion; and in, The threaded opening is sized to allow the retaining screw to advance into a locking position within the threaded opening, wherein the tail portion of the retaining screw is flush with or spaced inward from the narrow outer surface of the body.

13. The cable fastener of claim 11, wherein the narrow outer surface is flat and the wide outer surface is also flat; and in, The main body includes a corner joint connecting the narrow outer surface and the wide outer surface.

14. The cable fastener of claim 11, wherein the fastener has a length, and the narrow outer surface and the wide outer surface extend a large portion of the length of the fastener.

15. The cable fastener of claim 11, wherein the body includes a head portion configured to be received in a connector of the fastener assembly.

16. The cable fastener of claim 15, wherein the body has a narrowed neck portion located between the head portion and the narrow and wide outer surfaces of the body.

17. The cable fastener of claim 11, wherein the body includes a head portion configured to be received in a connector of the fastener assembly; and in, The head portion includes a partially spherical head surface for engaging with a partially spherical surface of the connector and allowing the fastener to move relative to the connector.

18. The cable fastener of claim 11, wherein the multi-row threaded opening comprises three rows of threaded openings spaced approximately 120 degrees apart around the hole.

19. The cable fastener of claim 11, wherein the body has a single, integral structure.

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