Two-Directional Flaking Roller for Conveyor Belt Alignment
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Solution Overview
Problem
Conveyor belt replacement in industrial or mining operations is inefficient due to high reliance on mobile plant and manual handling, leading to poor control of belt guiding and alignment, resulting in inefficiencies and potential damage to equipment.
Innovation Solution
A conveyor belt flaking system utilizing a two-directional flaking roller, cable winch, support pipes, belt support A-frames, and hold-back drums to reduce manual handling and improve alignment, with the two-directional flaking roller enabling even laying and alignment of belt segments along a flake run.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If state of the art methods of conveyor belt replacement are used, then belt replacement can be performed, but high manual handling work content and reliance on mobile plant are required, resulting in poor control of belt guiding and alignment
Solution Approach 1:
The patent introduces a flake run as an intermediary structure that provides a controlled pathway for belt replacement. This flake run includes guide rails and alignment features that mediate between the old belt and new belt, enabling precise positioning and reducing manual alignment work while improving control accuracy
Solution Approach 2:
The system enables self-alignment through the flake run structure, where the belt segments automatically guide themselves into proper position using the guide rails and alignment features built into the flake run, eliminating the need for high manual handling work content while maintaining precision
2Productivity
If state of the art methods of conveyor belt replacement are used, then belt replacement can be performed, but reliance on mobile plant is high, leading to inefficiency of operations and lost time
Solution Approach 1:
The patent divides the belt replacement process into discrete segments that can be installed independently on the flake run. This segmentation allows for systematic, efficient installation without requiring complex mobile plant equipment, reducing both device complexity and improving productivity through organized workflow
Solution Approach 2:
The flake run is prepared in advance with guide rails, alignment features, and support structures before belt replacement begins. This preliminary action eliminates the need for complex mobile plant during the actual replacement operation, reducing device complexity while improving operational efficiency
Data Source
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AI summary
Conveyor belt flaking systems include a plurality of conveyor belt segments, each of the segments having opposing splice-able distal ends, a cable winch positioned proximate to a first end of the conveyor belt flaking system and at least one of the plurality of conveyor belt segments positioned proximate an opposing second end of the flaking system, a plurality of support pipes for supporting the conveyor belt segments when laid in a flake run of the conveyor belt flaking system, at least one hold-back drum insertable into one of the plurality of support pipes, a plurality of belt support A-frames for securing a cable from the cable winch and supporting one of the plurality of conveyor belt segments when introduced onto the flake run, and a two directional flaking roller attachable to the cable from the cable winch.