Elastomer Mixing Hose Automation with Beveled Edge Joining
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Solution Overview
Problem
Current methods for producing toothed or V-ribbed belts require significant manual labor and result in a high reject rate due to the need for custom molds for varying belt sizes and the complexity of making endless belts with embedded force carriers.
Innovation Solution
An automated method involving the fabrication of an elastomer mixture plate with beveled edges, which are then joined using gripping devices and a press beam to form a tube with a constant thickness, allowing for efficient production of hoses with variable circumferential lengths without the need for multiple tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom molds are used for each belt size, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
A single adjustable mold assembly is designed to produce multiple belt sizes by modifying the elastomer mixture plate dimensions and bevel angles rather than requiring separate dedicated molds for each belt size. The mold core and mold sleeve can accommodate different plate sizes through adjustment mechanisms.
Solution Approach 2:
The mold system incorporates adjustable components that allow dynamic reconfiguration for different belt circumferential lengths. The center distance between forming wheel and tensioning wheel can be varied, and the elastomer mixture plate dimensions can be adjusted to produce different belt sizes with one mold assembly.
2Adaptability or versatility
If manual assembly is used for elastomer mixture hoses, then adaptability is improved, but productivity deteriorates
Solution Approach 1:
The elastomer mixture plate is pre-cut with complementary beveled edges at the required angles before assembly. This preliminary preparation enables automated gripping and joining operations to proceed efficiently without requiring manual measurement and adjustment during assembly.
Solution Approach 2:
Manual assembly operations are replaced with automated gripping devices that use vacuum or mechanical clamps to hold the elastomer mixture plate edges, and automated pressing mechanisms to join the beveled edges. This substitution maintains flexibility while dramatically increasing production speed.
3Productivity
If automated processing is implemented, then productivity is improved, but manufacturing precision may deteriorate
Solution Approach 1:
Complementary asymmetric beveled edges are cut at specific angles (e.g., 30°) on opposite edges of the elastomer mixture plate. When these asymmetric surfaces are joined together, they create a uniform joint thickness that compensates for variations in plate thickness, ensuring consistent hose wall thickness in the joint area even with automated processing.
Solution Approach 2:
The automated pressing mechanism incorporates control systems that monitor and adjust pressing force and duration to ensure consistent joint quality. Sensors can detect joint area thickness and provide feedback to the pressing system to maintain precision across all produced hoses.
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 significantly reduces manual labor and reject rates, enabling higher production volumes of toothed or V-ribbed belts with consistent quality and circumferential lengths, while eliminating the need for custom molds.
Implementation Method 1
The two edges 13, 15 of the elastomer mixture plate 12 can be held by the two gripping devices 8a, 8b, in particular by means of vacuum
Implementation Method 2
The two complementarily beveled side surfaces can be connected by pressing using the press beam mentioned
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
Method and apparatus (1) for the automatic production of an elastomer mixing hose (17), in particular an elastomer mixing hose (17) for the production of timing belts or multi-ribbed V-belts, comprising a device (2) for preparing an elastomer mixing sheet (12), a device (7) for producing an elastomer mixing hose (17) from the prepared elastomer mixing sheet (12), and a device (18) for preparing timing belts or multi-ribbed V-belts from an elastomer mixing hose (17). The method and apparatus according to the invention increase the production rate per unit of time and reduce the amount of rejects.