Cable Conveyor Belt Fastener Assembly for Flexible Heavy-Duty Splicing
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Solution Overview
Problem
Conventional methods for repairing and connecting steel cable conveyor belts are labor-intensive, time-consuming, and impractical for heavy-duty applications, especially in remote locations, due to the high skill and specialized tools required, and existing mechanical splices may not withstand the extreme forces and narrow cable spacing of these belts.
Innovation Solution
A fastener assembly with cable fasteners and connectors that allow for secure connections between cable end portions, enabling shifting and pivoting to accommodate belt movement, while using durable materials and set screws to secure the cables, reducing stress and preventing pull-out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional vulcanized splicing is used to connect conveyor belt ends, then high strength and durability are achieved, but the repair process becomes extremely time-consuming and requires specialized tools and facilities
Solution Approach 1:
The splice assembly is divided into separate modular components: cable fasteners that attach to individual cable ends, connectors that join the fasteners, and independent adjustment mechanisms. This segmentation allows each component to be installed and adjusted separately, dramatically reducing repair time while maintaining the structural integrity needed for heavy-duty applications.
Solution Approach 2:
The connector incorporates adjustable elements that allow the splice assembly to adapt to cable movement, tension changes, and misalignment. This dynamic capability enables the mechanical splice to withstand operational stresses without requiring the rigid, time-intensive vulcanization process, thus reducing downtime while preserving reliability.
2Loss of time
If mechanical splices are used to reduce repair time, then downtime is minimized, but the splices may not withstand the extreme forces of heavy-duty conveyor belts
Solution Approach 1:
The connector combines multiple materials with complementary properties: hardened steel components for strength and wear resistance, flexible elements for accommodation of cable movement, and friction-based locking mechanisms for secure attachment. This composite approach creates a mechanical splice that matches or exceeds the strength of vulcanized splices while maintaining rapid installability.
Solution Approach 2:
The cable fastener incorporates a curved or spherical contact surface that distributes load across a broader area of the cable end. This geometric feature increases the bearing surface and reduces stress concentration, allowing the mechanical connection to withstand the extreme forces of heavy-duty conveyor operations without failing.
3Stability of the object's composition
If cable fasteners are rigidly fixed to connectors, then connection stability is improved, but the ability to accommodate belt movement and pulley navigation is reduced
Solution Approach 1:
The fastener assembly exhibits different mechanical properties at different locations: rigid fixed points provide stable anchoring to the cable, while flexible or adjustable sections accommodate movement and misalignment. This localized variation in stiffness allows the splice to remain stable under load while adapting to dynamic operational conditions.
Solution Approach 2:
The connector includes movable components such as adjustable clamps, sliding elements, or spring-loaded mechanisms that allow the fastener position to shift within controlled limits. This dynamic capability enables the splice to navigate pulleys and accommodate belt movement without compromising the overall stability of the connection.
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
The fastener assembly provides a durable and efficient method for connecting steel cable conveyor belt ends, minimizing downtime and improving durability by allowing for flexible movement and stress relief, suitable for heavy-duty operations.
Implementation Method 1
a first plurality of locking members to secure the first cable fastener to the first cable end portion
Implementation Method 2
set screws in the threaded through openings that are operable to secure the cable end portion in the bore
Implementation Method 3
the first and second pockets and the first and second head portions configured to permit shifting of the first and second cable fasteners relative to the connector during operation of the cable conveyor belt
Data Source
AI summary
In one aspect, a fastener assembly for joining first and second cable end portions of a cable conveyor belt. The fastener assembly includes a first cable fastener having a first head portion and a first plurality of locking members to secure 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 to secure 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 configured to permit shifting of the first and second cable fasteners relative to the connector during operation of the cable conveyor belt.