Endless Reinforced Belt Manufacturing with Embedded Helical Cords
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Solution Overview
Problem
Existing methods for manufacturing endless reinforced belts are inefficient, inaccurate, and often require splices that weaken the belt and limit the length and width of the belts produced, with exposed cords reducing the belt's strength and longevity.
Innovation Solution
A system using a single rotatable cylindrical mandrel with a complementary profile to produce belts of varying lengths and widths, featuring a cord applicator for helical tension member embedding and a laminator for embedding the cord between elastomeric layers, ensuring no exposed cords and improved pitch control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a cylindrical mandrel of defined diameter is used to produce endless belts, then the belt length is fixed to a specific value, but the adaptability to produce different belt lengths is limited
Solution Approach 1:
The mandrel is made adjustable in diameter through hydraulic or mechanical expansion mechanisms, allowing the same mandrel to produce belts of different lengths by changing its effective diameter during operation
Solution Approach 2:
A single mandrel structure serves multiple functions by being able to produce various belt lengths and potentially different belt profiles through adjustment mechanisms, replacing the need for multiple fixed-diameter mandrels
2Length of moving object
If splicing methods are used to join belt ends, then belts of any length can be produced, but the splice creates a weak point that reduces load capability and lifetime
Solution Approach 1:
The tensile cord is fed continuously through the belt manufacturing process without interruption or splicing, maintaining the continuous load-bearing path and eliminating weak points while allowing production of belts of any length
3Manufacturing precision
If mold flights are used to support tensile cords during manufacturing, then the cords can be positioned accurately, but exposed cords remain on the belt surface reducing strength
Solution Approach 1:
The mold flights are removed from the system and replaced with a alternative cord positioning mechanism that does not leave exposed cords on the belt surface, such as using a smooth mandrel with cord embedding grooves
4Shape
If grooved rolls are used to impart profile into belts, then the belt profile can be formed, but pitch control accuracy is insufficient
Solution Approach 1:
The mechanical grooved roll profiling system is replaced with a precision mandrel that has grooves cut directly into its surface, combined with synchronous cord feeding mechanisms that accurately control pitch based on mandrel rotation
Data Source
AI summary
A system, method and apparatus for making endless belts having a profile layer, a fully embedded, helically wound, cord layer, and a top layer. The apparatus has a rotatable mandrel (2) with a profile complementary to the belt profile (1), two or one engagement rolls adjacent the mandrel to maintain forced, wrapped engagement of the profile layer on a portion thereof; a cord applicator which may include a heated blade (5) that plows a groove in the profile layer into which the cord is laid and fused thereto. A laminator applies the top layer onto the reinforced carcass. A system of buffer rolls (14) handles the loose portion of the profile layer or carcass guiding it.