Conveyor Belt Abrasion Detection via Embedded Sensor Relocation
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Solution Overview
Problem
The existing method for manufacturing endless conveyor belts with embedded detection objects faces challenges in accurately measuring the abrasion of the main body portion due to the detection object being embedded in a joining portion with a different thickness, making it difficult to obtain accurate abrasion data for the main body portion.
Innovation Solution
A manufacturing method where the detection object is embedded in the top surface side of the finite conveyor belt, rather than the joining rubber member, allowing for high-accuracy abrasion measurement by forming a laminated body with a core layer member interposed between unvulcanized top and bottom cover rubber members, and vulcanizing it to create the conveyor belt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the detection object is embedded in the joining rubber member, then the joining portion can be detected, but the abrasion of the main body portion cannot be measured with high accuracy
Solution Approach 1:
The detection object is extracted from the joining rubber member and relocated to the main body portion of the top cover rubber part. This allows the detection object to measure abrasion of the main body portion directly, eliminating the measurement error caused by thickness differences between the joining portion and main body portion.
Solution Approach 2:
The detection object serves as an intermediary element that is embedded in the main body portion rather than the joining portion. This intermediary placement enables accurate measurement of main body portion abrasion while the joining rubber member maintains its separate function for joining the finite conveyor belts.
2Manufacturing precision
If the joining rubber member is made thicker than the finite cover rubber part, then vulcanization can be controlled, but the detection object embedding position becomes problematic
Solution Approach 1:
The conveyor belt structure is segmented into distinct functional zones: the joining rubber member for joining operations and the main body portion for material conveyance. The detection object is placed in the main body portion, separating the detection function from the joining function, allowing both vulcanization control and accurate abrasion measurement to coexist.
3Measurement precision
If the detection object is embedded in the main body portion, then accurate abrasion measurement is achieved, but the joining rubber member design becomes more flexible
Solution Approach 1:
The detection function is extracted from the joining rubber member and relocated to the main body portion. This extraction simplifies the joining rubber member design, allowing it to focus solely on its joining function without the constraint of accommodating a detection object, thereby reducing design complexity.
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 method enables precise measurement of the abrasion of the main body portion of the endless top cover rubber part, allowing for accurate detection and analysis, while also allowing for easier design of the joining rubber member and improved manufacturing accuracy.
Implementation Method 1
a vulcanization step of vulcanizing the laminated body by pressurizing in the belt thickness direction and heating the laminated body to form the finite conveyor belt
Implementation Method 2
a detection object which is abraded according to an amount of abrasion of a surface of the finite top cover rubber part
Data Source
AI summary
A manufacturing method of a finite conveyor belt of the present invention includes a laminated body formation step of forming a laminated body (35) in which a core layer member (32) which includes a tensile body (14) is interposed between an unvulcanized top cover rubber member (33) and an unvulcanized bottom cover rubber member (34) in a belt thickness direction T, and a vulcanization step of vulcanizing the laminated body (35) by pressurizing in the belt thickness direction (T) and heating the laminated body to form a finite conveyor belt, and the laminated body formation step includes a member formation step of forming the top cover rubber member (33) by separately connecting both ends of an unvulcanized first cover rubber part (36) in a belt length direction (L) in which a detection object (15) is embedded with ends of an unvulcanized second cover rubber parts (37) in the belt length direction (L).