Steel-Strand Reinforced Belt Layout to Prevent Core Migration
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Solution Overview
Problem
Existing belt reinforcement technologies face issues with core migration and noise generation due to the wicking of central core filaments under repetitive load cycles, leading to belt failure and discomfort in elevator operations.
Innovation Solution
A belt design featuring steel strands with a specific diameter-to-pitch ratio greater than 0.55, oriented parallel to each other within a polymer jacket, and coated with an organic primer to enhance adhesion, preventing core migration and noise by ensuring proper anchoring and reducing the risk of steel strands cutting through the polymer jacket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-strand steel cords are used for belt reinforcement, then the belt achieves good jacket anchoring and low creep, but the central core filaments wick out under repetitive load cycles causing core migration and belt failure
Solution Approach 1:
The invention removes the problematic central core filament from the strand construction. By using only outer layer filaments arranged in a hexagonal pattern without a central core, the design eliminates the source of core migration while maintaining the structural integrity and anchoring properties of the strand.
Solution Approach 2:
The strand is segmented into discrete outer layer filaments arranged in a specific hexagonal pattern rather than using a continuous central core. This segmentation allows each filament to be independently positioned and anchored, preventing the wicking effect that occurs in centrally-coreled strands.
2Strength
If steel strands with larger diameter are used to increase strength, then the belt achieves higher breaking load, but the strands cut through the polymer jacket more easily
Solution Approach 1:
The invention applies local quality by creating surface irregularities and variations in filament diameter distribution along the strand. This non-uniform local structure increases the surface area and creates mechanical interlocking with the polymer jacket, preventing cutting through while maintaining overall strand strength.
Solution Approach 2:
The strand uses a composite construction with filaments of different diameters and materials (steel and stainless steel) arranged in a hexagonal pattern. This composite structure provides both high strength and improved interaction with the polymer jacket through varying surface characteristics.
3Ease of manufacture
If traditional multi-strand construction is used, then the manufacturing process is well-established, but the repetitive tension-compression cycles cause peristaltic action that moves the core forward
Solution Approach 1:
By removing the central core entirely and using only outer layer filaments in a hexagonal arrangement, the invention eliminates the peristaltic action mechanism. Without a central core to push forward during compression cycles, the strand maintains its structural integrity through repeated tension and compression loading.
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 solution provides a belt with improved strength, reduced noise, and increased fatigue life by maintaining the core within the strand, ensuring the belt's structural integrity and user comfort.
Implementation Method 1
coated with an organic primer to enhance adhesion
Data Source
AI summary
A belt for use as for example an elevator belt, flat belt, synchronous belt or toothed belt comprises steel strands held in parallel by a polymer jacket. The steel strands have a diameter ‘D’ and are separated by a pitch ‘p’. The ratio of diameter ‘D’ over pitch ‘p’ is larger than 0.55. Such belt arrangement prevents the cutting of the polymer jacket between strand and pulley and abates the noise generation during use. The belts are best built with a type of parallel lay strands particularly designed for use in a belt. These strands do not show core migration during use of the belt.