Automatic tensioning apparatus and method of use

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Solution Overview

Problem

Existing floor cleaning systems face challenges in maintaining optimal tension in tensile members, leading to inefficiencies, wear, and maintenance issues due to variable debris loads and lack of precise tension control, resulting in suboptimal performance and reduced component lifespan.

Innovation Solution

An automatic tensioning apparatus with a longitudinally extending stationary base frame, translatable drive frame, drive assembly, and sensor-controlled actuators that adjust tension dynamically based on the position of the drive frame to maintain optimal preload, using hydraulic or pneumatic actuators to manage slack and adjust pressure accordingly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual tensioning systems with lead screws or hydraulic cylinders are used, then the operator can adjust tension, but the system lacks precise automatic control and requires continuous operator intervention

Engineering Contradiction:

Improvetension adjustmentVSAvoidautomatic tension control

Core Design Contradiction:

Ease of operationVSExtent of automation

Solution Approach 1:

The tensioning system automatically monitors and adjusts tensile member tension without operator intervention. The system uses sensors to detect tension levels and actuators to make real-time adjustments, enabling the system to service itself and maintain optimal tension continuously.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system incorporates sensors that continuously monitor the position of the drive frame and tensile member tension, feeding this information back to the controller. The controller processes this feedback and automatically actuates the tensioning mechanism to maintain optimal tension, creating a closed-loop control system.

Inventive Principle:

Principle #23Feedback

2Duration of action of moving object

If excessive tension is applied to the tensile member, then slack is removed and the circuit can run longer, but wear and stretching of the tensile member increases

Engineering Contradiction:

Improvecircuit run timeVSAvoidtensile member wear

Core Design Contradiction:

Duration of action of moving objectVSLoss of substance

Solution Approach 1:

The system dynamically adjusts tension based on real-time conditions rather than maintaining a fixed high tension. The automatic tensioning system monitors drive frame position and debris load changes, adjusting tension dynamically to match actual operational needs, thereby extending tensile member life while maintaining circuit operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the tension parameter automatically based on detected conditions such as drive frame position and debris accumulation. By adjusting the tension parameter in response to changing operational conditions, the system prevents both excessive tension (which causes wear) and insufficient tension (which causes slack and stopping).

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If the drive frame position is not automatically monitored, then the system is simpler, but tension cannot be dynamically adjusted based on actual position

Engineering Contradiction:

Improvesensor and control systemVSAvoidtension control precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The system replaces manual mechanical tension adjustment with an automated system using sensors, controllers, and actuators. The sensor detects drive frame position, the controller processes this information, and the actuator automatically adjusts tension, substituting electronic control for manual mechanical operation to achieve precise tension control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution ensures consistent and optimal tensioning, reducing wear, energy wastage, and maintenance needs, while automatically compensating for tensile member stretch and debris load changes, thereby enhancing system performance and longevity.

Implementation Method 1

using hydraulic or pneumatic actuators to manage slack and adjust pressure accordingly

Methodology Applied

Scientific EffectHydraulic pressure: Hydraulic Press

Implementation Method 2

using hydraulic or pneumatic actuators to manage slack and adjust pressure accordingly

Methodology Applied

Scientific EffectPneumatic pressure: Pressure Increase

Data Source

PatentUS11821495B2Automatic tensioning apparatus and method of use

Publication Date: 2023.11.21 PATZ CORP

AI summary

An automatic tensioning apparatus is provided that includes a tensioning drive unit having: a longitudinally extending stationary base frame with a plurality of guides extending between a lower portion and an upper portion, and a plurality of rotatable feed wheels axially secured at the lower portion, as well as a translatable drive frame slidably coupled to the plurality of guides with a drive assembly coupled to the drive frame, the drive assembly including a drive motor and a tensile member interface for engaging and rotationally translating a tensile member. The tensioning drive unit further including a plurality of drive frame actuators actuatable to move the drive frame between a bottom frame position and a top frame position, as well as a sensor for at least indirectly sensing the position of the drive frame along a longitudinal base frame axis.