Rapid-Release Belt Splicer Prevents Sticking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional splicing presses struggle with thermoplastic conveyor belt materials like polyester, which tend to stick to the heating wand during the splicing process, leading to material loss and a compromised joint quality.
Innovation Solution
A belt splicer with a toggle linkage assembly and spring mechanism that rapidly releases the clamp jaws, applying a force impulse to separate the melted butt ends from the heating wand, preventing material sticking and ensuring clean separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional splicing presses are used with thermoplastic materials like polyester, then the splicing process can be completed, but the material sticks to the heating wand causing loss of belt material and compromised joint quality
Solution Approach 1:
The clamp jaw assembly incorporates a rapid release mechanism that dynamically changes the clamping force from a sustained static force during heating to a rapid dynamic separation force. This dynamic action cleanly separates the melted belt material from the heating wand before it can stick, eliminating material loss and maintaining joint quality
Solution Approach 2:
The clamp jaw assembly applies preliminary clamping force to hold the belt sections in precise alignment before heating begins. This preliminary positioning ensures that when the material melts and is subsequently rapidly separated, the joint maintains proper alignment and quality without material loss to the heating wand
2Manufacturing precision
If the clamp jaws are held closed during heating to maintain alignment, then proper splicing alignment is achieved, but the melted material sticks to the heating wand
Solution Approach 1:
The rapid release mechanism transforms the static clamping state into a dynamic separation state. During heating, clamps maintain alignment; upon release, they rapidly accelerate the belt sections away from the heating wand, preventing sticking while preserving the alignment achieved during the heating phase
Solution Approach 2:
The rapid release mechanism causes the clamp jaws to rush through the separation process so quickly that the melted material does not have time to adhere to the heating wand. This rapid action skips the problematic sticking phase entirely, maintaining both alignment precision and preventing material loss
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 rapid release mechanism effectively prevents material sticking, maintaining joint quality and efficiency in splicing thermoplastic conveyor belts, including those made of polyester.
Implementation Method 1
A spring mechanism is attached between the toggle linkage assembly and the clamp jaws. The toggle linkage assembly is operable from a locked state to a released state. In the locked state of the toggle linkage assembly, the spring mechanism has a high level of stored energy and pushes the clamped jaws toward each other. In the released state, the spring mechanism rapidly releases its stored energy to accelerate the clamped jaws rapidly apart.
Implementation Method 2
A heating wand is moved into the gap, and the two clamps close until the butt ends of the belt sections contact opposite sides of the heating wand. As soon as the butt ends are softened or melted sufficiently by the wand's heat
Data Source
Figure 1~2
Figure 3~5
Figure 4A~4C
AI summary
A belt splicer for butt-welding conveyor belts and methods for its operation. The belt splicer has clamp jaws (12,13) that close to contact the butt edges of two belt sections (26,27) against opposite ends of a heating wand (60) and to hold the two melted butt edges together as they weld to each other. A toggle linkage assembly (36) locks the clamped jaws closed and stores energy in a spring mechanism (56,57). The toggle linkage assembly allows the rapid release of the spring energy to accelerate the clamp jaws open to pull the melted butt ends rapidly away from the sides of the wand to avoid sticking. In another version, an air cylinder is used instead of the toggle linkage assembly and spring mechanism to close and rapidly open the splicer.