Modular Sheave Sleeve Design for Belt Alignment and Low-Cost Repair
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Solution Overview
Problem
The high cost and difficulty in manufacturing and repairing idler sheaves with contoured outer surfaces for elevator systems, as well as the need for surface plating and specific customization, pose challenges in maintaining belt alignment and tension efficiently.
Innovation Solution
A modular sheave unit comprising a ball bearing with an outer and inner sleeve, where the sleeves are made from materials like aluminum, plastic, or thermoplastic polyurethane, reducing the need for plating and allowing for easy replacement, and featuring a belt receiving groove for improved belt alignment and reduced friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If idler sheaves are manufactured with contoured outer surfaces to ensure belt alignment, then belt alignment is improved, but manufacturing cost increases
Solution Approach 1:
The sheave is divided into two functional parts: a simple contoured outer surface for belt alignment and a complex contoured inner surface for belt tensioning. By segmenting the functions, the outer surface can be manufactured using simpler, less costly processes while the inner surface receives the necessary complex contouring.
Solution Approach 2:
Complex contoured surfaces are applied only where needed (inner surface for tensioning) rather than the entire sheave. The outer surface maintains a simpler contour for alignment purposes, reducing overall manufacturing complexity and cost while maintaining belt alignment functionality.
2Manufacturing precision
If idler sheaves are manufactured with contoured outer surfaces to maintain belt alignment, then belt alignment is improved, but repair difficulty increases
Solution Approach 1:
The sheave components are segmented into replaceable parts. When wear or damage occurs, individual components can be replaced without requiring complex repair processes, maintaining belt alignment functionality while simplifying maintenance.
Solution Approach 2:
The design accepts that contoured surfaces will wear over time and incorporates easy replacement mechanisms. Rather than attempting complex repairs to restore contoured surfaces, the system enables straightforward replacement of worn components, reducing repair difficulty.
3Reliability
If surface plating is applied to idler sheaves for customization and performance, then durability is improved, but manufacturing complexity increases
Solution Approach 1:
Surface plating or specialized materials are applied only to specific areas of the sheave where durability is most critical, such as the belt contact surfaces. This localized approach maintains durability while reducing overall manufacturing complexity compared to plating the entire component.
Solution Approach 2:
The sheave incorporates composite construction with different materials for different functions: base structural material for strength and contoured surface materials for durability and belt interaction. This composite approach achieves durability requirements while managing manufacturing complexity through material selection rather than complex processing.
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 modular design lowers manufacturing and maintenance costs, enhances belt alignment, and extends the usage life of the sheave units by reducing friction and enabling easy customization and replacement.
Implementation Method 1
a bearing that includes an outer race, an inner race and one or more rolling elements therebetween
Data Source
AI summary
Disclosed is a modular sheave unit including: a bearing that includes an outer race, an inner race and one or more rolling elements therebetween; and a sleeve that includes one or both of: an outer sleeve axially surrounding the outer race, the outer sleeve including an outer surface defining a groove, the groove configured to receive a belt; and an inner sleeve axially surrounded by the inner race and disposed between the inner race and a mandrel.