Endless Belt Production Using Removable Connecting Elements
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Solution Overview
Problem
Current methods cannot automate the production of an endless strip from multiple metal sheets, requiring manual manufacturing steps due to the inability to bend and weld multiple sheets simultaneously.
Innovation Solution
A method involving a removable connecting element to form a composite panel from multiple metal sheets, which can then be processed automatically, using tension belts to shape and weld the sheets into an endless strip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple metal sheets are processed manually to form an endless strip, then manufacturing flexibility is maintained, but productivity is low and automation is not achieved
Solution Approach 1:
The metal sheets are divided into individual units that can be independently handled and connected. Each sheet is processed separately through the forming device, and connecting elements are used to join them into an endless strip, enabling automated high-speed production while maintaining flexibility in sheet selection and arrangement.
Solution Approach 2:
Connecting elements serve as intermediaries between individual metal sheets. These elements facilitate the automated connection process by providing standardized interfaces that can be quickly joined and disconnected, enabling the transition from manual to automated manufacturing while maintaining production flexibility.
2Extent of automation
If metal sheets are welded together to achieve desired strip length, then the endless strip can be formed, but the process requires manual operations and cannot be fully automated
Solution Approach 1:
The system is designed to automatically perform forming, positioning, and connecting operations without manual intervention. The connecting elements are automatically positioned and joined to metal sheets through the forming device, enabling the process to serve itself and achieve full automation while managing complexity through standardized procedures.
Solution Approach 2:
The invention changes the connection method from permanent welding to removable connecting elements that can be automatically attached and detached. This parameter change in the joining mechanism enables automated operation while reducing process complexity through reversible, standardized connections that are easier to control mechanically than welding processes.
3Adaptability or versatility
If a single metal sheet is processed, then the existing method works, but it cannot produce endless strips from multiple sheets
Solution Approach 1:
The forming device is designed with universal capabilities to process multiple metal sheets through the same automated sequence. The device can handle different sheet configurations and lengths by using interchangeable connecting elements, maintaining manufacturing simplicity while achieving versatility in producing endless strips from multiple sheets.
Solution Approach 2:
Metal sheets are prepared in advance with connecting elements attached to their edges before entering the forming device. This preliminary action of pre-assembly simplifies the manufacturing process by reducing the complexity of in-line operations, while enabling the system to handle multiple sheets efficiently through standardized pre-prepared components.
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
Enables the automated and efficient production of endless strips from multiple metal sheets, allowing for the creation of durable belts suitable for various applications, such as wheel drive belts and laminated corrugated board production.
Implementation Method 1
free end edges of the composite panel, which opposite the edges of the metal sheets arranged in the at least one connecting element, are bent towards one another and welded to one another
Implementation Method 2
the metal sheets connected to one another to form the plate assembly are brought into an annular shape in a holding device by means of tension belts
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
The invention relates to a method for producing an endless belt (1) from at least two plate-shaped metal plates (2, 3, 4), wherein the at least two metal plates (2, 3, 4) are introduced into one of two opposing fixtures of at least one removable connection element (5a, 5b), one edge (9, 10, 11, 12) of each metal plate leading, and form a composite board (6), whereupon free end edges (7, 8) of the composite board (6) which lie opposite the edges (9, 10, 11, 12) of the metal plates arranged in the at least one connection element, are bent towards one another and welded together, whereon the at least one connection element (5a, 5b) is removed and the edges (9, 10, 11, 12) of the metal plates (2, 3, 4) connected to one another beforehand by the at least one connection element (5) are bent towards one another and welded together.