Hybrid Yarn Conductor Loop for Conveyor Belt Corrosion
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Solution Overview
Problem
Conveyor belt conductor loops face issues with corrosion, low flexibility, limited extensibility, and unreliable connections due to their susceptibility to mechanical stress and material properties, leading to false alarms and reduced service life.
Innovation Solution
A conductor loop formed by hybrid yarns with a textile core and corrosion-resistant conductive sheath, such as polyamide and silver, which are galvanically or electrochemically sheathed to create a flexible and durable circuit, allowing for a longer service life and improved structural design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel cords are used in conductor loops to provide strength and conductivity, then the structural integrity is improved, but corrosion resistance deteriorates
Solution Approach 1:
The conductor loop uses a composite structure combining steel cords for strength and copper wires for conductivity and corrosion resistance. The copper wires are stranded and arranged in parallel with the steel cords, creating a hybrid conductor that leverages the advantages of both materials - the steel provides tensile strength while the copper provides electrical conductivity and resistance to corrosion.
2Adaptability or versatility
If meandering structure is used to increase extensibility, then the flexibility is improved, but the lifetime deteriorates due to material ductility requirements
Solution Approach 1:
The conductor loop employs a dynamic meandering configuration where the conductive elements can flex and deform elastically during conveyor belt operation. The meandering pattern allows the conductor to extend and retract repeatedly without permanent deformation, adapting to the dynamic mechanical stresses of belt flexing while maintaining structural integrity over extended service periods.
Solution Approach 2:
The conductor uses flexible stranded wire construction with multiple thin copper wires bundled together, allowing the conductor to bend and flex without breaking. This flexible stranded structure, combined with the meandering layout, enables the conductor to accommodate repeated flexing cycles of the conveyor belt while maintaining electrical continuity and structural integrity.
3Reliability
If copper stranded wires are used to improve conductivity and corrosion resistance, then the electrical properties are improved, but the structural strength deteriorates
Solution Approach 1:
The conductor loop merges copper stranded wires and steel cords into a single integrated conductive element. The copper wires and steel cords are stranded together in parallel arrangements, combining the high electrical conductivity and corrosion resistance of copper with the high tensile strength of steel. This hybrid construction allows the conductor to simultaneously achieve excellent electrical properties and mechanical strength.
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
The hybrid yarn conductor loop achieves high flexibility and conductivity, reducing false alarms and extending the service life of conveyor belts by enhancing material resistance and connection reliability.
Implementation Method 1
which are galvanically or electrochemically sheathed to create a flexible and durable circuit
Implementation Method 2
which are galvanically or electrochemically sheathed to create a flexible and durable circuit
Data Source
AI summary
A conductor loop and a conveyor belt including the conductor loop. The conductor loop is embedded in an article having a base of a polymer material with elastic properties. The conductor loop includes at least one hybrid yarn having at least a textile first material and a conductive second material closed in an endless manner.