Pulley-Based Tensioning for Long Endless Traction Means
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Solution Overview
Problem
Existing dynamic tensioning systems for endless traction devices face challenges in maintaining optimal pretension, especially with long systems, as they require increased travel distances and space, contradicting dynamic control and leading to system complexity.
Innovation Solution
The introduction of a second deflection element interacting with the endless traction means in the manner of a pulley, utilizing rollers aligned coaxially or at an angle, with guides to prevent contact, and a controllable actuator like a hydraulic cylinder to reduce travel distance and increase force, allowing for dynamic force control while maintaining actuator size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single deflection element is used for tensioning long endless traction devices, then the actuator must cover large travel distances to maintain required preload, but this increases the installation space requirement and impedes dynamic control
Solution Approach 1:
A second deflection element is introduced as an intermediary component between the actuator and the endless traction device. This creates a pulley system where the second deflection element acts as a mediator that changes the force transmission path, allowing the actuator to maintain preload over longer distances without requiring proportionally larger installation space.
Solution Approach 2:
The pulley system with two deflection elements transforms the linear travel distance requirement into a rotational mechanism. By converting the actuator's linear motion into rotational motion of the pulley system, the effective force application is extended over longer distances while keeping the actuator's physical footprint compact.
2Reliability
If the actuator travel distance is increased to maintain preload in long tension systems, then the required pretension force can be maintained, but the dynamics of the tensioning force control deteriorates
Solution Approach 1:
The second deflection element serves as a mechanical intermediary that amplifies the actuator's motion. This allows small, rapid actuator movements to produce larger effective displacements in the tensioning system, thereby maintaining fast dynamic response despite the longer overall travel distance required for pretensioning.
Solution Approach 2:
By introducing the pulley mechanism with two deflection elements, the system transforms the relationship between actuator travel and tensioning effect. The mechanical advantage provided by the pulley system allows the actuator to operate with smaller, faster movements while still achieving the necessary tensioning force changes over the extended distance.
3Reliability
If multiple actuators are used to ensure required pretension in long endless tension systems, then the pretension can be maintained, but the device complexity increases
Solution Approach 1:
The second deflection element acts as a mechanical multiplier that allows a single actuator to effectively control tension over long distances. This intermediary component enables one actuator to perform the work that would otherwise require multiple actuators, thereby maintaining reliability while reducing system complexity.
4Ease of manufacture
If a conventional clamping system is used for long endless tensioning devices, then the system can be implemented, but the travel distance requirement increases which impedes dynamic control
Solution Approach 1:
The pulley system with two deflection elements introduces a mechanical intermediary that decouples the relationship between actuator travel distance and tensioning effectiveness. This allows the system to maintain dynamic control capability by enabling the actuator to operate with smaller, faster movements while still achieving the necessary tensioning over long distances.
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 configuration enhances dynamic control of tensioning force, reduces the required travel distance, and minimizes installation space, effectively addressing the limitations of existing systems by enabling efficient pretensioning of long endless traction devices.
Implementation Method 1
the second deflection element is designed to interact with the first deflection element and the endless traction means in the manner of a pulley
Data Source
Figure 1a~1b
Figure 2
AI summary
The invention relates to a tensioning system for endless tension members comprising an actuator and a first deflection element, wherein the actuator interacts with the first deflection element and wherein the actuator enables the first deflection element to be moved relative to the endless tension member in order to change the pretension of the endless tension member. According to the invention, the tensioning system includes a second deflection element, wherein the second deflection element engages with the endless tension member and wherein the second deflection element is configured to interact with the first deflection element and the endless tension member in the manner of a pulley system.