Woven Elevator Belt Structure With Reduced Tension Member Spacing
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Solution Overview
Problem
Traditional load carrying members in elevator systems, such as round steel ropes, often leave grooves on the exterior surface, leading to noise issues when interacting with sheaves and are costly to manufacture, while flat belts with tension member cords encased in a jacket face challenges in achieving optimal load distribution and support due to limitations in weaving techniques.
Innovation Solution
A method of creating a woven fabric by weaving load supporting tension members and cross fibers, shrinking the cross fibers to reduce spacing between tension members, and coating the assembly with a jacket to cover the tension members, allowing for closer spacing and improved load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional weaving techniques are used to manufacture flat belts with tension member cords, then the manufacturing process is simple, but the spacing between tension members cannot be optimized leading to poor load distribution
Solution Approach 1:
The cross fibers are pre-positioned during weaving at a first spacing, then later shrunk to achieve the desired second spacing. This preliminary arrangement allows the weaving process to be simpler while still achieving precise final spacing control through the subsequent shrinking step.
Solution Approach 2:
The spacing between tension members is controlled by changing the physical state of cross fibers through shrinking. The cross fibers transition from an initial spaced arrangement to a compressed arrangement, thereby adjusting the spacing parameter between tension members to achieve optimal load distribution.
2Object-affected harmful factors
If round steel ropes are used in elevator systems, then the structure is simple, but grooves are left on the exterior surface causing noise when interacting with sheaves
Solution Approach 1:
A jacket layer is applied over the woven fabric and tension members to create a smooth exterior surface. This flexible shell eliminates the grooves that would otherwise interact with sheaves and generate noise, while the underlying woven structure maintains the load-bearing functionality.
Solution Approach 2:
The elevator belt is constructed as a composite structure combining woven fabric, tension member cords, and an outer jacket. This composite approach integrates the load-bearing function of the woven tension members with the noise-reducing smooth surface of the jacket layer.
3Strength
If cross fibers are shrunk to reduce spacing between tension members, then load distribution is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The mechanical weaving process is supplemented with a thermal or chemical shrinking process for the cross fibers. This substitution allows the achievement of precise spacing control and improved load distribution that cannot be obtained through weaving alone, while the shrinking process can be integrated into existing manufacturing lines.
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 method enables the production of a stronger and stiffer load bearing member with reduced spacing between tension members, enhancing load distribution and support in elevator systems, while minimizing noise and manufacturing costs.
Implementation Method 1
shrinking at least some of the cross fibers to thereby decrease the spacing between the adjacent ones of the tension members
Data Source
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AI summary
An exemplary method of making a woven fabric includes weaving a plurality of load supporting tension members and a plurality of cross fibers together into a woven fabric. A spacing between adjacent ones of the tension members has a first dimension. At least some of the cross fibers are shrunk to thereby decrease the spacing between the adjacent ones of the tension members to a second, smaller dimension. In another example, two woven fabrics are positioned next to each other. The two fabrics include a spacing between adjacent tension members having a first dimension. At least one tension member of one woven fabric is aligned with and between two of the tension members of the other fabric to thereby decrease the spacing to a second, smaller dimension.