TITLE OF THE INVENTION: AUTOMATED BELT TENSIONING SYSTEM AND METHOD

FIELD OF THE INVENTION

The present invention relates to a belt tensioning system and method.

BACKGROUND OF THE INVENTION

Conventionally, belt tensioners of the mechanical type have been widely used for maintaining proper tensioning of the belt. The belt tensioners employed are engaged or disengaged to engage or disengage power transmission. In such belt tensioning mechanisms, the belt tension has to be reset after a first working cycle, say after 24hrs. In addition, to ensure that the belt is in the required state of tension, the tension of the belt is to be checked periodically. Checking the belt periodically to determine if it is in the required state of tension and resetting it if necessary is a skilled process, and is very highly dependent on the operator's skill and is therefore very subjective and may not be consistent. Improper tensioning may result in power transmission failure if tension value is above or under the required threshold. There is therefore a need in the art for an automated belt tensioning mechanism that can solve the above mentioned drawbacks and has the below mentioned objectives.

OBJECTIVES OF THE INVENTION

An objective of the present invention is to provide an automated belt tensioning mechanism.

Another objective of the present invention is to provide an automated belt tensioning mechanism, which maintains the belt under a state of tension without loosening/slackening the belt, thus increasing the efficiency of power transmission.

Yet another objective of the present invention is to provide an automated belt tensioning mechanism, which is consistent and eliminates the need for any skilled man power, thus saving time.

SUMMARY OF THE INVENTION

To overcome the drawbacks of the prior art and accomplish the above mentioned objectives, an automated belt tensioning system is disclosed. The system comprises a drive module comprising a drive pulley, which drives a driven pulley by employing a belt which travels between the drive pulley and the driven pulley. The system also comprises a tensioner pulley, a metal shaft comprising a first end and a second end and a pivot point, a cylinder with a piston, an actuating valve and at least two fluid flow points, say a first flow point that is associated with a head end of the cylinder and a second flow point that is associated with a cap end of the cylinder; wherein the tensioner pulley is associated with the first end of the metal shaft and the piston of the cylinder is associated with the second end of the metal shaft; the end of the cylinder that is linearly opposite the end that is associated with the second end of the metal shaft is fixed with a fixing point of a stand; and the metal shaft is rotatable in both a clockwise and a counter-clockwise direction with respect to the pivot point. The cylinder may be a hydraulic cylinder or a pneumatic cylinder. The system may also further comprise a source of pressurized gas.

To slacken the belt, the actuating valve is activated, causing fluid (hydraulic oil or pressurized gas) to flow through the least resistance path into the cap end of the cylinder. This causes the piston to extend causing the metal shaft to rotate in the clockwise direction and thus the tensioner pulley moves away from the belt. This causes the belt to slacken.

To maintain the belt under a state of tension, the actuating valve is activated and a pressure regulatory unit is operated to cause fluid to flow through the second flow path into the head end of the cylinder. This causes the piston to retract causing the metal shaft to rotate in the counter-clockwise direction and thus tensioner pulley comes into contact with the belt. This causes the belt to tighten, thereby maintaining the belt under a state of tension.

BRIEF DESCRIPTION OF DRAWINGS:

Figure 1 shows the present invention with the belt in slackened state i.e. when the tensioner pulley is not in contact with the belt, when the cylinder is hydraulic.

Figure 2 shows the present invention with the belt under a state of tension i.e. when the tensioner pulley is in contact with the belt, when the cylinder is hydraulic.

Figure 3 shows the metal shaft, in accordance with the present invention.

Figure 4 shows the present invention with the belt in slackened state i.e. when the tensioner pulley is not in contact with the belt, when the cylinder is pneumatic.

Figure 5 shows the present invention with the belt under a state of tension i.e. when the tensioner pulley is in contact with the belt, when the cylinder is pneumatic.

DETAILED DESCRIPTION OF DRAWINGS

As shown in Figures 1 and 2, the present invention comprises a drive module comprising a drive pulley (117), which drives a driven pulley (116) by employing a belt (118) which travels between the drive pulley (117) and the driven pulley (116). In order to maintain the driving operation of the drive pulley (117) and the driven pulley (116), it is necessary to maintain the belt (118) under a state of tension, as illustrated via Figure 2. However, when the drive module is not required to be operative, the belt (118) may be maintained in a slackened state, as illustrated via Figure 1. The present invention also comprises a tensioner pulley (101), a metal shaft (103), a cylinder (109) with a piston (106) and an actuating valve (112). The metal shaft (103) comprises a first end (102), a second end (105) and a pivot point (104). The tensioner pulley (101) is associated with the first end (102) of the metal shaft (103) and the piston (106) of the cylinder (109) is associated with the second end (105) of the metal shaft (103). The end of the cylinder (109) that is linearly opposite the end that is associated with the second end (105) of the metal shaft (103) is fixed with a fixing point (110) of a stand (111). The metal shaft (103) is rotatable in both a clockwise (203) and a counter-clockwise (204) direction with respect to the pivot point (104), the same is illustrated in Figure 3. The cylinder (109) also comprises at least two fluid flow points, say a first flow point (107) that is associated with a head end of the cylinder (109) and a second flow point (108) that is associated with a cap end of the cylinder (109).

Conventionally, over a period of driving operation, say, 24 hours, it is observed that the belt (118) slackens slightly, thereby affecting the driving operation of the driven pulley (116). To prevent this occurrence, conventionally, the tightening of the belt (118) is reset by manually adjusting it. However, tensioning the belt manually is cumbersome, as an operator is required to be stationed permanently near the belt (118) to confirm that the value of the tension that the belt (118) is subjected to, is the appropriate value.

To solve this conventional problem, the present invention employs the tensioner pulley (101). The belt (118) is subjected to tension when the tensioner pulley (101) comes into contact (202) with the belt (118). Likewise, the belt (118) is in a slackened state when the tensioner pulley (101) is not in contact (201) with the belt (118). The tensioner pulley (101) is controlled by the direction of rotation (203, 204) of metal shaft (103) with respect to the pivot point (104). The direction of rotation (203, 204) of the metal shaft (103) with respect to the pivot point (104) is controlled by the cylinder (109) and the actuating valve (112).

Initially, the actuating valve (112) is activated, causing fluid to flow through the least resistance path i.e. via a first flow path (113) into the cap end of the cylinder (109) vide the second flow point (108). This causes the piston (106) to extend causing the metal shaft (103) to rotate in the clockwise (203) direction and thus the tensioner pulley (101) moves away (201) from the belt (118). This causes the belt to slacken, said condition being depicted in a manner clearly understandable to a person skilled in the art through Figure 1.

On the other hand, to maintain the belt (118) under a state of tension, the actuating valve (112) is activated and a pressure regulatory unit (115) is operated to cause fluid to flow through a second flow path (114) into the head end of the cylinder (109) via the first flow point (107). This causes the piston (106) to retract causing the metal shaft (103) to rotate in the counter-clockwise (204) direction and thus tensioner pulley (101) comes into contact (202) with the belt (118). This causes the belt (118) to tighten, thereby maintaining the belt (118) under a state of tension, said condition being depicted in a manner clearly understandable to a person skilled in the art through Figure 2.

The metal shaft (103) may be made of any metal or metal alloy that provides sufficient strength. Preferably, the metal shaft (103) is made of stainless steel. In one embodiment, the cylinder (109) may be hydraulic and the fluid may be hydraulic oil. In an alternate embodiment, the cylinder (109) may be pneumatic and the fluid may be pressurized gas. The hydraulic cylinder is preferably a double acting cylinder. In case the cylinder (109) is pneumatic, the disclosed system further comprises a source of pressurized gas (119), as depicted in Figures 4 and 5. The pressurized gas is preferably pressurized air.

It will be apparent to a person skilled in the art that the above description is for illustrative purposes only and should not be considered as limiting. Various modifications, additions, alterations, and improvements without deviating from the spirit and the scope of the invention may be made by a person skilled in the art.

LIST OF REFERENCE NUMERALS
101 - Tensioner Pulley
102 - Metal Shaft - First end
103 -Metal Shaft
104 - Metal Shaft - Pivot Point
105 - Metal Shat-Second end
106 -Piston
107 - First Flow Point
108 - Second Flow Point
109 -Cylinder
110 - Cylinder fixing point
111 -Stand
112 - Actuating valve
113 - First Flow Path
114 - Second Flow Path
115 - Pressure Regulatory Unit
116 - Driven Pulley
117 -Drive Pulley
118 -Belt
119 - Source of pressurized gas
201 - Tensioner pulley Direction (Backward)
202 - Tensioner pulley Direction (Forward)
203 - Clockwise rotation of metal shaft
204 - Counter-clockwise rotation of metal shaft

We claim:

1. An automated belt tensioning system, comprising:
a drive module comprising a drive pulley (117), which drives a driven pulley (116) by employing a belt (118) which travels between the drive pulley (117) and the driven pulley (116);

a tensioner pulley (101);

a metal shaft (103) comprising a first end (102) and a second end (105);

a pivot point (104), wherein the metal shaft (103) is rotatable in both a clockwise (203) and a counter-clockwise (204) direction with respect to the pivot point (104), said rotation of the metal shaft (103) controlling the tensioner pulley (101);

a cylinder (109) with a piston (106), wherein the cylinder (109) is a hydraulic cylinder or a pneumatic cylinder;

an actuating valve (112), wherein the cylinder (109) and the actuating valve (112) control the direction of rotation of the metal shaft (103) about the pivot point (104); and

at least two fluid flow points, including a first flow point (107) that is associated with a head end of the cylinder (109) and a second flow point (108) that is associated with a cap end of the cylinder (109), said fluid being hydraulic oil (hydraulic cylinder) or pressurized gas (pneumatic cylinder) from a source of pressurized gas (119), wherein:

the tensioner pulley (101) is associated with the first end (102) of the metal shaft and the piston (106) of the cylinder (109) is associated with the second end (105) of the metal shaft (103); and
the end of the cylinder (109) that is linearly opposite the end that is associated with the second end (105) of the metal shaft (103) is fixed with a fixing point (110) of a stand (111).

2. The automated belt tensioning system as claimed in claim 1, wherein the cylinder (109) is a double acting cylinder.

3. The automated belt tensioning system as claimed in claim 1, wherein the metal shaft (103) is made of any metal or metal alloy.

4. The automated belt tensioning system as claimed in claim 3, wherein the metal shaft (103) is made of stainless steel.

5. The automated belt tensioning system as claimed in claim 1, wherein the belt (118) is under a state of tension when the tensioner pulley (118) is in contact with the belt (118).

6. The automated belt tensioning system as claimed in claim 1, wherein the belt (118) is in a slackened state when the tensioner pulley (118) is not in contact with the belt (118).

7. The automated belt tensioning system as claimed in claim 1, wherein the pressurized gas is pressurized air.

8. An automated belt tensioning method, comprising the steps of:

a. maintaining a belt (118) in a slackened state, which comprises the steps of:

i. activating an actuating valve (112);

ii. flowing of fluid through the least resistance path via a first flow path (113) into a cap end of a cylinder (109) vide a second flow point (108;

iii. extension of a piston (106) which causes a metal shaft (103) to rotate in the clockwise (203) direction; and

iv. moving away of a tensioner pulley (101) from the belt (118); or

b. maintaining the belt (118) under a state of tension, which comprises the steps of:

i. activating the actuating valve (112) and operating a pressure regulatory unit (115);

ii. flowing of fluid through a second flow path (114) into a head end of the cylinder (109) via a first flow point (107);

iii. retraction of the piston (106) which causes the metal shaft (103) to rotate

in the counter-clockwise (204) direction; and

iv. coming into contact of the tensioner pulley(101) with the belt (118), wherein the cylinder (109) is a hydraulic cylinder and the fluid is hydraulic oil, or the cylinder (109) is a pneumatic cylinder and the fluid is pressurized gas from a source of pressurized gas (119).

9. The automated belt tensioning method as claimed in claim 8, wherein the hydraulic cylinder is a double acting cylinder.

10. The automated belt tensioning method as claimed in claim 8, wherein the metal shaft (103) is made of any metal or metal alloy.

11. The automated belt tensioning method as claimed in claim 10, wherein the metal shaft (103) is made of stainless steel.

12. The automated belt tensioning method as claimed in claim 8, wherein the pressurized gas is pressurized air.