Hydraulic Crusher Belt Tensioning for Safe Maintenance Access
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Solution Overview
Problem
Conventional belt tensioning devices for crushers are manually operated, posing safety risks to operatives due to proximity to nip points and moving parts, and suffer from misalignment and vibration issues, with conventional shock absorbers prone to damage from dirt accumulation.
Innovation Solution
A remotely operable crusher belt tensioning apparatus with a tension arm having a short and long arm portion, operated by a hydraulic cylinder, allowing safe belt tensioning and maintenance, featuring a tension drum outside the belt path for easy access, adjustable bearings for alignment, and semi-bonded bushes for shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manually operated belt tensioning devices are used, then belt tensioning can be performed, but safety risks increase due to proximity to nip points and moving parts
Solution Approach 1:
The belt tensioning device is designed to automatically tension the belt without requiring manual intervention. The tensioning drum is automatically positioned and the belt is automatically tensioned through the mechanical action of the drum rotating, eliminating the need for operatives to manually tension belts in close proximity to dangerous moving parts
Solution Approach 2:
The manual mechanical tensioning operation is replaced with an automated mechanical system where the tensioning drum is driven by the belt itself or by a separate drive mechanism, automatically positioning the drum and applying tension without human intervention near the nip points
2Reliability
If the tensioning drum is positioned within the path of the belt, then tension can be applied, but accessibility to the tensioning drum is reduced and injury risk increases
Solution Approach 1:
The tensioning drum is positioned in a location that is not within the path of the belt, effectively moving it to another dimensional space. The drum is arranged to engage the belt from the side or from above/below the belt path, allowing operatives to access and maintain the drum from a safe position outside the belt's operational envelope
3Reliability
If conventional spring type shock absorbers are used, then vibration and tension forces can be absorbed, but they are susceptible to dirt accumulation causing cracks and failure
Solution Approach 1:
The shock absorber is designed as a simple, robust component that can be easily replaced. Rather than designing a complex sealed system, the invention uses a basic spring or elastomeric element that is inexpensive and can be quickly swapped out when worn or contaminated, minimizing downtime and maintenance complexity
Solution Approach 2:
The shock absorber is positioned and designed to absorb shocks and vibrations before they can damage critical components such as the crusher housing, drive shaft, or belt tensioning mechanism. The cushioning element is pre-installed in the load path to protect the structure from impact forces during operation
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 apparatus reduces safety hazards, ensures optimal belt alignment and tensioning, minimizes belt misalignment and vibration, and extends equipment lifespan by eliminating the need for manual operation and reducing downtime.
Implementation Method 1
a hydraulic cylinder attached to the relatively short arm portion between a first belt tensioning operating position in which the tension drum applies tension to the belt and a second belt non-tensioning maintenance position in which the belt is removable from the tensioning apparatus
Implementation Method 2
The apparatus includes a shock absorber to dampen shock on the apparatus. The shock absorber may have semi-bonded bushes
Data Source
AI summary
A crusher belt tensioning apparatus is arranged for being mounting on a crusher having a driven crusher pulley to actuate a crusher, a drive pulley drivable by a power unit, a belt extending between the crusher pulley and the drive pulley to transfer drive from the power unit to the crusher, and a tension drum mounted on a tension arm for applying a tension force to the belt. The tension arm includes a first relatively short arm portion and a second relatively long arm portion connected to the first relatively short arm portion. The tension drum is movable by a hydraulic cylinder, attached to the relatively short arm portion, between a first belt tensioning operating position in which the tension drum applies tension to the belt and a second belt non-tensioning maintenance position in which the belt is removable from the tensioning apparatus.