Offset Cleat Pattern Prevents Roll-Back on Inclined Conveyor Belts

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conveyor belts in the agriculture and mineral extraction industries face challenges in preventing material roll-back, especially when operating at inclines, which increases energy consumption and can lead to material pinching and misalignment.

Innovation Solution

A unique cleat configuration on the conveyor belt, featuring offset and uniquely shaped vertical and horizontal cleats arranged in specific patterns, prevents roll-back by ensuring continuous contact with drive rollers and reducing the risk of material pinching, while allowing the belt to form a tubular shape without intersecting cleats.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional conveyor belts without cleats are used, then the belt structure is simple and easy to manufacture, but material roll-back occurs when operating at inclines

Engineering Contradiction:

Improveprevention of material roll-backVSAvoidbelt structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The belt surface is segmented into multiple discrete cleats arranged in specific patterns (e.g., alternating side patterns, offset patterns). Each cleat acts as an independent element that collectively prevents material roll-back while maintaining manufacturing simplicity through modular construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Cleats are designed with asymmetric features including offset positioning from the belt centerline, varying heights, and non-uniform spacing patterns. This asymmetry creates effective material containment while allowing the belt to flex and form tubular shapes without cleat interference

Inventive Principle:

Principle #4Asymmetry

2Reliability

If cleats are added to prevent roll-back, then material roll-back is prevented, but energy consumption increases

Engineering Contradiction:

Improveprevention of material roll-backVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

Cleats are strategically positioned only where needed for material containment rather than covering the entire belt surface. The offset and patterned arrangement ensures cleats engage material only during critical phases of conveyance, reducing overall friction and energy consumption while maintaining roll-back prevention

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cleat configuration provides slightly more containment than minimum required, with offset patterns that create effective material barriers. This partial over-engineering ensures reliable roll-back prevention across varying load conditions without requiring excessive cleat density that would increase energy consumption

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If cleats are added to prevent roll-back, then material roll-back is prevented, but material pinching and misalignment occur

Engineering Contradiction:

Improveprevention of material roll-backVSAvoidmaterial pinching and misalignment

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Cleats are arranged in multi-dimensional patterns including offset positions, varying depths, and staggered configurations across the belt width. This dimensional complexity in arrangement prevents material pinching by creating gradual containment rather than sharp edges, while maintaining effective roll-back prevention

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The offset cleat patterns are designed to gradually guide and contain material as it progresses along the belt, preventing sudden pinching actions. The staggered arrangement creates a progressive containment effect that maintains material alignment while preventing roll-back

Inventive Principle:

Principle #10Preliminary action

4Quantity of substance

If the belt forms a tubular shape to receive product, then carrying capacity increases, but cleats may intersect causing material pinching

Engineering Contradiction:

Improvecarrying capacityVSAvoidmaterial pinching from intersecting cleats

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

Cleats are positioned asymmetrically with offset patterns that account for the tubular formation of the belt. The offset arrangement ensures that when the belt curves into a tube, cleats from opposite sides do not align and intersect, preventing material pinching while maintaining full carrying capacity

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The cleat pattern is segmented and distributed around the belt circumference with intentional spacing and offset positioning. This segmentation ensures that during tubular formation, cleats remain spatially separated and do not create pinching points, while collectively providing full material containment capability

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9517886B2Cleated conveyor belt

Publication Date: 2016.12.13 UNVERFERTH MFG CO INC

AI summary

A belt includes one or more devices that prevent roll-back of material being conveyed by the belt wherein the one or more devices are formed as a pattern on the belt. The pattern includes one of the one or more devices being offset from at least another of the one or more devices. The pattern is at distance from another pattern of the one or more devices formed on the belt.