Conveyor Belt Flow Control Cleats for Spillage Reduction
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Solution Overview
Problem
Conveyor belts with prior art cleat configurations face issues such as increased wear, product damage due to contact, and potential for products to fall off, leading to reduced operational capacity and increased horsepower requirements.
Innovation Solution
A conveyor belt design featuring a unique configuration of two sets of cleats oriented at acute angles to the side edges, which creates recesses to securely hold objects and reduce movement, thereby minimizing wear and spillage while enhancing operational capacity and reducing rolling resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If V-shaped cleats are used to prevent objects from falling off the conveyor, then spillage is minimized, but objects can move with respect to the conveyor belt increasing wear and contact between objects causing damage
Solution Approach 1:
The cleat structure is segmented into multiple sections (first cleat section, second cleat section, third cleat section) that work together to create discrete recesses. Each segment serves a specific function: the first two sections form the walls of the recess while the third section provides the base, collectively creating secure product containment without excessive movement.
Solution Approach 2:
The recess structure acts as an intermediary element between the conveyor belt and the product. By providing a dedicated holding space with controlled geometry, the recess mediates the interaction between moving belt and stationary product, preventing harmful relative motion while maintaining secure containment.
2Productivity
If cleats are added to increase product capacity on the conveyor, then operational capacity is enhanced, but rolling resistance and horsepower requirements increase
Solution Approach 1:
The cleat design changes key geometric parameters including the angle ranges (30-60 degrees for first and second cleat sections, 10-30 degrees for third section), height variations, and spacing configurations. These parameter optimizations reduce rolling resistance while maintaining product containment effectiveness, thereby lowering energy requirements.
Solution Approach 2:
Different sections of the cleat structure have different local qualities optimized for their specific functions. The first and second cleat sections have steeper angles for containment, while the third section has a gentler angle for reduced friction. This localized optimization allows high product capacity with minimized energy consumption.
3Stability of the object's composition
If cleats are configured to hold objects securely, then product stability is improved, but manufacturing complexity increases
Solution Approach 1:
The cleat configuration uses asymmetric angle ranges for different sections (30-60 degrees for containment sections, 10-30 degrees for the base section) rather than uniform angles. This asymmetric design provides superior product stability while remaining manufacturable through standard molding or fabrication processes.
Data Source
AI summary
A conveyor belt with flow control cleats including belting, a first set of cleats and a second set of cleats. The belting has a first side edge and a second side edge. The first set of cleats has a plurality of first cleat sections. The first set of cleats are oriented at a first acute angle with respect to the first side edge. The second set of cleats has a plurality of second cleat sections. The second set of cleats are oriented at a second acute angle with respect to the second side edge.