Pendulum Coupled Tension Rollers for Compact High-Torque Belt Drives
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Solution Overview
Problem
Existing belt drives with tensioning systems require significant installation space and have complex assembly processes, limiting their ability to efficiently transmit high torques while preventing slippage.
Innovation Solution
The belt drive features eccentrically pivoted tensioning rollers connected via a pendulum support, allowing the first tensioning roller on the load side to pivot the second roller on the slack side, increasing belt tension without external components, and optimizing the mechanical structure for reduced space and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a pressure roller is used to press the belt against the drive pulley to transmit high torques, then the torque transmission capability is improved, but the assembly complexity and installation space increase due to the required rocker mechanism with external fulcrum
Solution Approach 1:
The patent combines the pressure roller and tensioning roller functions into a single integrated tensioning device. The tensioning device includes a first tensioning roller for the tight side and a second tensioning roller for the slack side, connected through a pendulum support. This merging eliminates the need for separate pressure rollers and external rocker mechanisms, reducing assembly complexity while maintaining high torque transmission capability through the coupled tensioning system.
Solution Approach 2:
The patent relocates the fulcrum from an external position (as in traditional rocker mechanisms) to an internal position within the belt drive system. The pendulum support is articulated to the tensioning rollers themselves, creating a self-contained tensioning system that reduces installation space and eliminates the need for external structural support, thereby simplifying the overall assembly.
2Power
If a rocker with external fulcrum is used for power transmission from tight side pressure roller to slack side pressure roller, then high torques can be transmitted, but the installation space is increased
Solution Approach 1:
The patent merges the fulcrum function into the internal structure of the tensioning device by using a pendulum support articulated to the tensioning rollers. This eliminates the need for an external rocker mechanism with an external fulcrum, significantly reducing the installation space required while maintaining the ability to transmit high torques through the coupled tensioning system.
Solution Approach 2:
The patent repositions the fulcrum from an external location to an internal location within the belt drive system. The pendulum support creates a compact, self-contained tensioning mechanism that fits within the existing belt drive footprint, eliminating the need for additional external space that would be required for traditional rocker mechanisms.
3Device complexity
If a rigid rod pendulum support is used to connect tensioning rollers, then the structure is simplified, but the space requirements and assembly complexity increase compared to integrated designs
Solution Approach 1:
The patent uses a pendulum support that is articulated to the tensioning rollers, allowing dynamic adjustment and movement. This dynamic connection enables the tensioning device to adapt to varying operational conditions while maintaining a compact structure. The articulated connection provides the necessary degrees of freedom for the tensioning rollers to move independently while remaining connected, reducing the overall space requirement compared to rigid rod connections.
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 installation space, ensures adequate force application on the slack side, and enhances rope friction management, enabling efficient high-torque transmission with reduced complexity and space requirements, suitable for both positive-locking and friction-locking belts.
Implementation Method 1
by pivoting the rope friction on the slack side in the opposite direction unrolling second tension roller is particularly favorably influenced both in terms of the wrap angle and in terms of the holding force
Implementation Method 2
a pendulum support eccentrically linked to the tensioning rollers in such a way that a pivoting of the first tensioning roller rolling on the tight side causes the second tensioning roller rolling on the slack side to pivot
Data Source
Figure 1
AI summary
Belt drive with drive pulley, driven pulley and tensioning device for a belt comprising a tensioning device with tensioning rollers, wherein the tensioning device has a first tensioning roller rolling on the load side of the belt and a second tensioning roller rolling on the slack side of the belt, with an endless belt encircling a drive pulley, driven pulley and tensioning rollers, wherein the tensioning rollers are each mounted eccentrically for pivoting and are connected to each other via a pendulum support eccentrically articulated to the tensioning rollers such that a pivoting of the first tensioning roller rolling on the load side under load or drive load causes a pivoting of the second tensioning roller rolling on the slack side in the sense of increasing the belt tension in the slack side