Challenge

The competitiveness of a high-volume industrial machine was being affected by poor service life and complexity within its mechanical power drive. Of particular concern were premature drive-belt failure and the complexity, cost and service life of the existing bearing arrangements.

Engineering Approach

A detailed investigation of the existing drive system was undertaken to identify the causes of belt-life limitations and evaluate alternative belt technologies and drive configurations. Mathematical models were developed and incorporated into a bespoke engineering application to optimise the belt drive and determine the design and stability requirements for automatic belt-tensioning systems. A spring loaded, damped tensioner was developed and the bearing arrangements were also fundamentally redesigned. A novel, substantially simpler bearing system was developed and implemented throughout the drive, reducing component count and cost while improving bearing life. Associated sheet-metal brackets and welded structures were designed, analysed, prototyped and tested.

Outcome

Belt service life was doubled, improving product competitiveness and directly contributing to increased market share. The redesigned belt and bearing systems also delivered significant cost savings while substantially simplifying manufacture, assembly and maintenance.