Modular Conveyor Units With Elastomeric Matrix
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Solution Overview
Problem
Existing conveyor systems, particularly in the mining industry, face challenges with belt wear and punctures from larger rocks, leading to increased downtime for replacement and potential leakage of fine materials.
Innovation Solution
A conveyor system unit comprising a pair of slats interconnected by an elastomeric matrix, forming a continuous carrying surface with hinged connections, allowing for independent replacement of units and enabling the use of scrapers on both the carrying surface and side walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conveyor belt is used to prevent leakage of fine material, then leakage is reduced, but the belt surface wears and can become ripped or punctured by larger rocks, requiring time-consuming replacement
Solution Approach 1:
The conveyor system is divided into modular conveyor system units, each comprising a pair of slats interconnected by an elastomeric matrix. These modular units can be independently replaced when damaged, eliminating the need to replace the entire conveyor belt. The elastomeric matrix itself is segmented into multiple units that can be individually swapped, directly reducing replacement time while maintaining leakage prevention capabilities through the continuous carrying surface formed by the elastomeric material.
2Strength
If steel feeder pans are used for heavy duty applications, then durability is improved, but fine material can leak through the gaps between pans
Solution Approach 1:
The conveyor system combines rigid slats (providing structural strength and durability) with an elastomeric matrix material (providing a continuous, gap-free surface). The slats form the structural framework that can withstand heavy loads and impacts, while the elastomeric matrix fills the gaps between slats to create a continuous carrying surface that prevents fine material leakage. This composite structure simultaneously achieves both durability and leakage prevention.
3Productivity
If a continuous conveyor belt is used, then material transport is efficient, but the entire belt must be replaced when any section is damaged
Solution Approach 1:
The conveyor system is divided into modular conveyor system units that can operate independently. Each unit comprises a pair of slats connected by an elastomeric matrix, forming a self-contained module. When one unit becomes damaged, only that specific unit needs to be replaced while the rest of the conveyor system continues operating. This segmentation maintains continuous material transport productivity while dramatically reducing downtime by limiting replacement scope to individual modules rather than the entire conveyor belt.
4Device complexity
If traditional conveyor systems are used, then construction is simple, but scrapers can only be applied to the carrying surface, not side walls
Solution Approach 1:
The elastomeric matrix serves multiple functions: it forms the continuous carrying surface, creates the side walls, and provides mounting surfaces for scrapers. The side walls are formed by the vertical portions of the elastomeric matrix extending from the slats, creating a unified structure where the same material and design principles apply to both the carrying surface and side walls. This universality allows scrapers to be effectively applied to both surfaces while maintaining construction simplicity through the integrated elastomeric matrix design.
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
This design reduces downtime for replacement by allowing individual units to be swapped independently, minimizes leakage through the use of scrapers on side walls, and maintains operational efficiency even with heavy loads and significant fines present.
Implementation Method 1
The first and second slats are interconnected by an elastomeric matrix extending across the supporting surfaces of the first and second slats
Implementation Method 2
The supporting side walls arranged on a same short edge side of the conveyor system unit are interconnected by an elastomeric matrix wall fastened to and extending across the supporting side walls
Data Source
AI summary
A conveyor system unit configured to form part of an endless conveyor system. A conveyor system unit includes a first slat and a second slat, and each slat has a supporting surface with a first and a second long side edge portion and two short side edge portions. The first and second slats are arranged side by side in view of each other and are interconnected by an elastomeric matrix extending across the supporting surfaces. Each conveyor system unit further includes supporting side walls arranged at each short side edge portion of each slat, and the supporting side walls arranged on a same short edge side of the conveyor system unit are interconnected by an elastomeric matrix wall extending across the supporting side walls. An endless conveyor system including such conveyor system units can be constructed.