Asymmetric Belt End Connector for Even Tension Member Loading
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Solution Overview
Problem
Existing methods for connecting the ends of tension members in belts or straps, such as steel cables, result in uneven spacing and oblique force transmission due to manufacturing inaccuracies, leading to wear, damage, and increased maintenance, particularly in conveyor belts used in mining.
Innovation Solution
A belt or belt segment design with clamping elements that are connected to the ends of tension members perpendicular to the longitudinal direction, with receiving spaces arranged asymmetrically to compensate for actual tension member positions, allowing for a positive-locking connection that transmits forces evenly and reduces wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the exposed steel ropes at each open end are inserted into longitudinal bores in hinge plates and fixed by crimping, then the connection can be made quickly and mechanically without on-site vulcanization, but the partial hinges can warp during pressing leading to increased wear and potential failure of the crenellated projections
Solution Approach 1:
The connecting element is divided into a hinge plate portion and a separate clamping element portion. The clamping element is inserted into the hinge plate through a receiving space, allowing the crimping operation to be isolated from the hinge plate. This segmentation prevents warping of the hinge plate during pressing while maintaining secure connection.
Solution Approach 2:
The clamping element acts as an intermediary component between the steel rope end and the hinge plate. It receives the crimping force directly, transferring it to the steel rope without requiring the hinge plate to undergo pressing, thus preventing warping while maintaining connection integrity.
2Ease of manufacture
If the hinge-like connecting elements are rotatably connected with crenellated projections and coupling rod, then the belt ends can be mechanically joined without vulcanization, but the crenellated projections and coupling rod are subject to significant wear during use and replacement is complex
Solution Approach 1:
The connecting element is segmented into a hinge plate with receiving space and a separate clamping element. This allows the clamping element to be replaced independently without removing the entire hinge assembly, simplifying maintenance while preserving the mechanical joining advantage.
Solution Approach 2:
The hinge plate maintains its rotatable connection capability with the coupling rod, preserving the dynamic adaptability of the belt end connection. Meanwhile, the static clamping element can be independently replaced, combining the benefits of mechanical flexibility and ease of maintenance.
3Productivity
If tension members are embedded in the core material with standard manufacturing processes, then the belt can be manufactured efficiently, but manufacturing inaccuracies result in uneven spacing and oblique force transmission leading to wear and damage
Solution Approach 1:
The receiving space in the connecting element is designed with an asymmetric orientation relative to the longitudinal centerline of the belt. This asymmetric design compensates for the systematic manufacturing inaccuracy in tension member spacing, allowing obliquely positioned tension members to be properly aligned and connected, thereby eliminating oblique force transmission while maintaining efficient manufacturing processes.
Data Source
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AI summary
The present invention relates to a belt (1) or a belt segment (1) with a plurality of longitudinally extending and parallel tension members (11), wherein the ends (12) of the tension members (11) are each force-fit connected to a clamping element (28), and to a connecting element (2) which forms a belt end (13) or a belt segment end (13) and is designed for connection with a further connecting element (2) of the other belt end (13) or a belt segment end (13) of a further belt segment (1), wherein the clamping elements (28) of the ends (12) of the tension members (11) are each received by a receiving space (24) of the connecting element (2) perpendicular to the longitudinal direction (X) and are held in a form-fit manner at least in the longitudinal direction (X).The belt (1) or belt segment (1) is characterized in that the receiving spaces (24) of the connecting element (2) are arranged in the transverse direction (Y) according to a predetermined division of the tension members (11) relative to each other and that the entirety of the receiving spaces (24) of the connecting element (2) is arranged offset in the transverse direction (Y) to the axis of symmetry (U) of the connecting element (2).