Conveyor Belt Link Wear-Resistant Welding Design
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Solution Overview
Problem
Conveyor belts experience wear and failure due to contact with drums and other propulsion devices, leading to increased maintenance and material costs, as existing wear prevention methods are either complex to manufacture or require excessive material usage.
Innovation Solution
A conveyor belt design featuring a first weld attaching a rod to a link, with a second, wear-resistant weld made of a different material covering the first weld and forming the outermost surface to contact the drive surface, providing enhanced abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single weld is used to attach the rod to the link, then the manufacturing process is simple, but the wear resistance is insufficient
Solution Approach 1:
The weld is divided into two distinct segments: a first weld for attaching the rod to the link, and a second wear-resistant weld covering the first weld. This segmentation allows each weld to have optimized properties for its specific function, resolving the contradiction between simplicity and wear resistance.
Solution Approach 2:
The second weld is applied locally only where wear resistance is needed (on the outer surface contacting the drive surface), while the first weld provides the primary attachment. This local differentiation of material properties solves the contradiction by adding complexity only where necessary for wear protection.
2Reliability
If link legs are extended to cover buttonheads, then wear protection is improved, but manufacturing complexity and material usage increase
Solution Approach 1:
Instead of modifying the link leg structure to provide wear protection, the invention extracts the wear protection function to a separate wearable component (the second weld). This keeps the link structure simple while still achieving wear protection through the removable, replaceable weld layer.
Solution Approach 2:
The solution uses composite construction by applying a second weld material with superior wear resistance properties over the first weld material. This composite approach provides enhanced wear protection without requiring complex link leg extensions, resolving the contradiction between protection and simplicity.
3Reliability
If more material is used for wear resistance, then durability is improved, but cost and weight increase
Solution Approach 1:
The second wear-resistant weld is applied partially, covering only the critical outer surface that contacts the drive surface. This partial application provides sufficient wear protection without using excessive material, resolving the contradiction between durability and material quantity.
Solution Approach 2:
The invention changes the material parameter of the weld by using a second weld material with different (superior wear resistance) properties. This parameter change achieves enhanced durability through material selection rather than through increased material quantity, resolving the contradiction between durability and material usage.
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 design significantly reduces wear and extends the lifespan of conveyor belts by using a more resistant material for the outer weld, minimizing material usage while maintaining structural integrity and reducing maintenance costs.
Implementation Method 1
The second weld material is different from the first weld material, and is more resistant to wear due to contact with the drive surface than the first weld material
Data Source
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AI summary
A conveyor belt is provided that includes a link having a leg formed of a link leg material, wherein the leg includes an outer link surface configured to face the drive surface, the link leg being configured to receive a rod. The conveyor belt may include an aperture extending through the leg, wherein the rod is disposed within the aperture. Also, the conveyor belt may include a first weld that attaches the free end of the rod to the outer link surface, the first weld comprising a first weld material and a second weld made of a second weld material, wherein the second weld covers at least a portion of the first weld and forms an outermost surface of the conveyor belt. The second weld material may be different from the first weld material, and may be more resistant to wear than the first weld material.