Multi-Stage Traction Belt Production for Reliable Layer Bonding
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Solution Overview
Problem
Existing methods for producing traction or suspension means made of elastomeric materials, such as elevator belts, face challenges with moisture absorption and contamination leading to poor bonding between layers, especially when multiple layers are required for enhanced fire protection, reduced friction, or specific profiles, which increases costs and risks of contamination and inadequate bonding.
Innovation Solution
A multi-stage production process where components are processed at room temperature and transferred to subsequent steps within a short time frame, maintaining a temperature range that minimizes moisture absorption and contamination, with each step optimizing layer adhesion and using polyurethane extruded at high temperatures for improved formability and bonding, allowing for the production of complex profiles like V-ribbed and double-profiled belts in fewer passes through the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional layers are applied by repeatedly passing belts through the system, then the required surface layers are achieved, but moisture absorption and contamination increase leading to poor bonding between layers
Solution Approach 1:
The manufacturing process is divided into multiple sequential stations, each adding a specific layer or component. This segmentation allows continuous production without repeated handling, as each station processes the belt in a single pass through the system.
Solution Approach 2:
The belt moves continuously through multiple stations in a single uninterrupted process. The continuous motion and single-pass methodology eliminate repeated stopping and handling, preventing moisture absorption and contamination that would occur during multiple passes through the system.
2Reliability
If polyurethane material is used for enhanced fire protection and reduced friction, then material performance is improved, but the material is hygroscopic and absorbs moisture from the environment leading to processing problems
Solution Approach 1:
The polyurethane layers are applied in a controlled manufacturing environment where moisture exposure is minimized. The process is designed to complete layer application quickly, preventing the hygroscopic material from absorbing excessive moisture before processing is complete.
Solution Approach 2:
The continuous single-pass manufacturing process minimizes the time polyurethane material is exposed to the environment. By completing all layer applications in one continuous operation rather than multiple separate passes, the total exposure time for moisture absorption is significantly reduced.
3Adaptability or versatility
If multiple layers and profiles are added to meet newer requirements, then functional performance is enhanced, but the complexity of the manufacturing process increases
Solution Approach 1:
Each manufacturing station is designed to perform multiple functions - applying layers, forming profiles, and bonding components all in sequence. The forming wheels and pressure rollers are configured to create various profiles and shapes, allowing a single pass through the system to achieve multiple manufacturing objectives.
Solution Approach 2:
The process combines layer application, profiling, and bonding operations into a single integrated manufacturing line. Multiple functional capabilities are merged into one continuous process, achieving enhanced product functionality without proportionally increasing process complexity.
4Manufacturing precision
If belts are passed through the system multiple times to achieve required surface layers, then complete coating is achieved, but production costs increase and bonding reliability decreases
Solution Approach 1:
The system applies all required surface layers in one continuous single-pass operation. The belt moves continuously through multiple stations that sequentially apply different layers, completing the entire coating process without stopping or reversing, thereby eliminating the need for multiple passes through the system.
Solution Approach 2:
The manufacturing process is segmented into specialized stations, each responsible for applying a specific layer or component. This segmentation allows all layers to be applied in sequence during a single pass, improving both completeness of coating and production efficiency.
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 method ensures secure bonding of individual layers, reduces production costs, and minimizes contamination risks, enabling the production of complex profiles with improved fire protection and reduced friction, while maintaining flexibility in production speed and temperature control.
Implementation Method 1
joined with the help of pressure rollers or roller-guided pressure bands acting on a circumferential sector of the forming wheels
Implementation Method 2
in which the elastomeric material is preferably extruded
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a process for the production, in a plurality of substeps, of a traction or carrying means () that is constructed from a plurality of components or assemblies and made of preferably extruded elastomeric material, wherein, in a first substep, a first component, provided with reinforcing members or cables, of the traction or carrying means is produced and, in further substeps, a traction or carrying means connected to further components or provided with further layers of elastomeric material, fabric layers or reinforcing-member layers is successively completed and said traction or carrying means is optionally shaped or profiled on one or more sides, wherein the individual substeps of the process follow one another such that a component processed or completed in the respectively preceding substep is fed at room temperature (Rt), after at most 1 to 10 minutes, preferably 2 to 5 minutes, to the next substep for further processing or completion, and such that the temperature of the component does not drop below 30° C, preferably 40° C, between a respectively preceding substep and the next substep.