Integrated Conveyor Belt Cutting and Splicing Apparatus
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Solution Overview
Problem
Existing conveyor belt joining methods are time-consuming, require additional equipment, and suffer from inaccuracies due to operator dependence and tolerance stackup issues, leading to inconsistent cuts and potential gaps or weaknesses in the welds.
Innovation Solution
A conveyor belt cutting and joining apparatus with an on-board cutting mechanism and non-contact heating device that supports the belt ends for simultaneous cutting and heating, eliminating the need for separate tools and reducing tolerance stackup by using the same belt supports for both operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate cutting tools and joining equipment are used, then flexibility in operation is maintained, but the process time increases and operator dependence causes inaccuracies
Solution Approach 1:
The patent combines the cutting mechanism and joining equipment into a single integrated apparatus. The cutting device with blade and guide rail is mounted on the same frame as the heating element and platen, allowing both operations to be performed in sequence without moving the belt between separate tools. This integration directly reduces process time while maintaining operational flexibility.
Solution Approach 2:
The platen serves multiple functions: it supports the belt during cutting operations and later supports the belt ends during heating and joining. The frame structure provides both guidance for the cutting blade and positioning for the heating element. This multi-functionality eliminates the need for separate equipment while preserving operational versatility.
2Manufacturing precision
If different support surfaces are used for cutting and heating operations, then operational flexibility is maintained, but tolerance stackup causes positioning inaccuracies
Solution Approach 1:
The patent uses a single platen surface for both cutting and heating operations. The belt is positioned on the same flat surface during cutting, then the heating element is positioned over the same surface area for joining. This eliminates tolerance stackup between different support surfaces while the integrated frame maintains the geometric relationship between cutting and heating positions.
Solution Approach 2:
The integrated frame acts as an intermediary structure that maintains precise geometric relationships between the cutting guide rail and the heating element positioning. The frame's rigid structure ensures that the relative positions of cutting and heating components remain constant, eliminating the need for separate support surfaces while maintaining alignment precision.
3Manufacturing precision
If manual cutting methods are used, then equipment simplicity is maintained, but operator dependence leads to inconsistent cuts and potential weld weaknesses
Solution Approach 1:
The patent replaces manual cutting with a mechanically driven blade system. The blade is moved along a fixed guide rail by a mechanical actuator, ensuring consistent cutting depth and angle without operator intervention. This mechanical system eliminates variability in cut quality while the guide rail ensures straight, accurate cuts that improve weld reliability.
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 enables consistent and precise cutting and joining of conveyor belt ends, reducing the time and effort required for the process while minimizing the risk of gaps or weaknesses in the welds, resulting in a stronger and more reliable joint.
Implementation Method 1
a non-contact heating device configured to be positioned between the conveyor belt ends for melting a portion of the belt material thereof
Implementation Method 2
a cutting mechanism operable to cut an end portion of at least one of the conveyor belt ends to remove at least a portion of belt material therefrom
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
A belt cutting and splicing apparatus is provided for joining together the ends of one or more monolithic conveyor belts. A belt support is configured to support the belt ends in spaced relation to each other and a non-contact heating device is provided for being disposed between the belt ends to generate thermal radiation for joining the belt ends together. A drive mechanism is operable to cause relative movement of a pair of platens, for supporting belt ends, toward and away from each other and a heating device between heating and stowed positions. An actuator of the drive mechanism is movable by an operator between at least three operation positions. An on-board belt cutting mechanism is provided for precision cutting of the belt ends using the same apparatus for both belt cutting and splicing operations.