Formed Wing Pulley Debris Displacement and Noise Reduction
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Solution Overview
Problem
Conventional wing pulleys in bulk material handling applications are limited by noise generation and structural weakness, leading to material recirculation and potential failure due to the straight wing design, which fails to effectively clear debris and maintain optimal belt traction.
Innovation Solution
A formed wing pulley with trapezoidal shaped wings, a polygon core, end disks, and clean-out ports is designed to enhance debris displacement, increase strength, and reduce noise, featuring a positive placement polygon core, end disks for structural reinforcement, and clean-out ports for accelerated debris removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If straight wings are used in conventional pulleys, then debris displacement capability is provided, but noise is generated and structural strength is limited
Solution Approach 1:
The patent applies curvature by transitioning from straight wings to formed (curved) wings that follow a circular arc profile. This curvature allows the wings to better follow the pulley's rotational path and belt contact surface, reducing impact shocks and noise while distributing structural stresses more evenly across the wing geometry, thereby improving both noise performance and structural strength.
Solution Approach 2:
The patent changes the geometric parameters of the wings by defining specific curvature radii, arc angles, and thickness distributions. These parameter changes optimize the wings to withstand centrifugal and impact forces better (improving strength) while reducing the slapping effect against the belt (reducing noise).
2Productivity
If straight wings are used in conventional pulleys, then debris displacement is achieved, but material recirculation occurs
Solution Approach 1:
The curved wing geometry creates a more effective sweeping motion that propels debris outward and away from the belt-pulley contact zone more efficiently. The arc-shaped wings follow the natural trajectory of material displacement, preventing material from falling back between the wings and being recirculated, thereby improving debris clearing efficiency and reducing material recirculation.
3Reliability
If straight wings are used in conventional pulleys, then belt cleaning function is provided, but wing failure occurs under increased loads
Solution Approach 1:
The patent optimizes wing parameters including increased thickness in critical stress zones, adjusted arc radii, and modified root attachments to the hub. These parameter changes enhance the wings' load-bearing capacity and resistance to bending and breaking under increased operational loads, thereby improving pulley reliability.
Solution Approach 2:
The curved geometry distributes mechanical stresses more favorably compared to straight wings, reducing stress concentrations at the wing roots and along the span. This curvature allows the wings to better accommodate flexural loads and impact forces, preventing catastrophic failure under increased loads.
Data Source
AI summary
A formed wing pulley for use in belt conveyor applications. The pulley consists of a plurality of formed wings with or without clean-out ports, mated to a positive placement polygon shaped core. The polygon core may be mated to hubs and/or end disks with centered hubs, which can be locked onto to a fixed or rotating shaft. Each formed wing of the pulley may be mated to the positive placement polygon core at the bottom side of the wing profile, and can have round, half round, hex, or flat wing tips that serve as the contact surface or the tops of wings may serve directly as the contact surface for the belt at the top side of the wing profile. When in assembled form, the formed wing pulley provides a set of radial wings that rotate about a central axis to support conveyor belt operation.