Quickly assembled and super strong -
How assembly times can be reduced to a minimum with ERO-Joint connectors
Quickly assembled and super strong -
How assembly times can be reduced to a minimum with ERO-Joint connectors
Operators of machines and plants know it only too well: If a drive belt or a conveyor belt has to be replaced, the machine is at a standstill for the time being. Even if replacement belts are readily available, installation may involve considerable effort. If the installation space and the position of the belt allow it, the belt ends can be welded in place using mobile welding equipment. If this is not possible, the only option is often the time-consuming dismantling of the machine in order to be able to fit the belt. The consequence: the machine, or in the worst case even the entire production line, is out of operation for hours.
Mechanical belt connectors are an alternative to welding. In this article, we would therefore like to present a product that can significantly reduce installation times. The "ERO Joint" assembly and fastening system developed by the Tanals company enables belts to be replaced in just a few minutes, depending on the situation. The system, which has been patented several times, is suitable for the simple and quick replacement of both drive belts and conveyor belts. Originally, the product was developed in partnership with Gates for their belts. Tanals, based in France, manufactures the ERO Joint connection systems itself.br>
This article will address the following questions, among others:
- How is a belt with mechanical ERO Joint connection structured?/li>
- Why does this splicing system outperform the strength of other mechanical belt joints?
- What other advantages does the method offer over other fastening methods?
- For what types of belts is the system suitable?
- For what types of belts is the system suitable?
- For which applications can the splicing system be used?
How is a belt with mechanical ERO Joint connection structured?
The belts themselves are commercially available drive or conveyor belts made of PU. The mechanical connector basically consists of tension cords embedded in polyurethane. The special feature here is that the tension cords are each placed in loops at the end. They thus enclose the future connection point and absorb the forces occurring there. Each connector consists of a pair of meander-cut belt ends that interlock exactly. These two halves are welded onto the two open belt ends and thus permanently connected to the belt. If desired, any coating can be easily applied over them, for example by bonding or welding. Once the belt has been prepared in this way, all that remains to be done at the installation site after threading is to close the belt ends with the aid of a single cross pin. This is usually made of steel or stainless steel.
Why does this splicing system outperform the strength of other mechanical belt joints?
ERO Joint HP connectors have been designed to have the same strength as a corresponding welded belt. According to the manufacturer, a belt equipped with this splicing system can replace a welded belt of the same nature without the need for further calculations. In general, an ERO Joint splice can withstand much higher tensile forces than many other mechanical joining systems. Systems from other manufacturers, which also use cross pins, only have the mechanical strength at the splice that the belt material (usually PU) provides. In contrast, the strength of an ERO Joint is based on the strength of the tension cords embedded and placed around the connection point. These are made of Vectran or Zylon fibers (an extremely durable and high-strength polymer).
What other advantages does the method offer over other fastening methods?
Since only a single hinge pin needs to be mounted when using ERO Joint HP, belts can be installed extremely easily and quickly. Special tools or training (such as for welding the belt ends) are not normally required. Repair times can be considerably reduced, production lines are therefore not at a standstill for hours.
For what types of belts is the ERO Joint system suitable?
The main product in the ERO Joint range is the ERO Joint HP timing belt connector. In the meantime, other versions are available that have been specially developed for drive belts, wide timing belts, synchronous belts, conveyor belts, round belts or V-belts. The only condition is: In order to be able to reliably weld the ERO Joint splice to the base belt, this must also be made of polyurethane.
In the width, there is theoretically no limit, apart from that of the belt itself. ERO Joint mechanical fastening systems are available for conveyor belts as thin as 1 mm. The joint is integrated into the conveyor belt in such a way that no change in width occurs, the belt cross-section is maintained and the belt remains compatible with conveyor belt scrapers.
For which applications can the ERO Joint HP splicing system be used?
Since ERO Joint belt connectors can be used to install belts in just a few minutes, they offer advantages wherever belt replacement is normally lengthy and complicated, and plant downtime is associated with high costs. The connection may even work where other splicing solutions reach their limits, are very inconvenient or very expensive. Two examples will illustrate this:
- The assembly of the belts under pretension
- The closing of the belt ends in case of very limited installation space
Challenge 1: The assembly of the belts under pretension
If a belt is to be installed under a certain basic tension, this can theoretically be achieved with a closed belt (welded or manufactured as a flex belt or sleeve). However, in order to install a closed belt, many parts of a machine or system often have to be dismantled in order to be able to insert the belt. Afterwards, all parts have to be reassembled. The only way to avoid this high installation effort is to use open belts, which are first threaded in and then closed when installed. However, welding the belt ends under tension is problematic, as is the installation of some mechanical fasteners that have to be connected by several pins at the same time. For this case, Tanals has developed its own assembly tools that allow easy joining of the belt ends even under tension.
Challenge 2: The closing of the belt ends in case of very limited installation space
If the installation conditions are very cramped, welding the belt ends is often not possible because the mobile welding equipment requires a certain amount of space. Mechanical connectors are also often impractical, depending on the number of pins to be fitted and, if necessary, assembly using special tools. Here, the ERO Joint HP connector with only one single hinge pin has a clear advantage, as it can still be closed even with minimal installation space.
Success story from glass industry
A project from the glass industry is intended to illustrate the improvements that can be achieved with the choice of a suitable belt connector. Background: Glass factories produce glass plates whose weight can vary from a few kilograms to several tons, depending on the size, thickness and type of glass used. Two main methods are used to transport these plates through the various stations of a plant: depending on the size and weight, either conveyor belts are used or roller conveyors driven by toothed belts. For example, a standard glass plate with a thickness of 4 mm and dimensions of 120 cm x 80 cm weighs approx. 6 kg and can still be moved with the help of a conveyor belt. A 15 mm thick tempered glass plate measuring 300 cm x 200 cm, on the other hand, can weigh up to 600 kg. Rollers are then used here.
At a certain manufacturer of glass plates, such roller conveyors were originally driven by welded belts, which are about 50 mm wide and 6000 to 8000 mm long. To replace a drive belt, the machine first had to be disassembled and then reassembled. This usually took between 4 and 6 hours, during which the plant was down. This was not only associated with considerable assembly costs, but above all with a significant loss of production.
To reduce downtime, the welded belts were replaced with corresponding belts with an ERO Joint HP connection, which have the same strength values. This now eliminates the need to disassemble the machine for belt replacement. The belt can simply be inserted and then locked with just one cross pin. With this method, the complete belt replacement takes only about 30 minutes, which means a reduction in downtime to about one tenth(!) of the original value.
Other products from the ERO Joint series
The main product in the Tanals portfolio is the ERO Joint HP timing belt splice. In addition, a wide range of joining solutions is now available for a wide variety of applications, for example for round belts from a diameter of 6 mm or V-belts with profiles from 10x6 mm. Depending on the application, installation is carried out either by means of the transverse fitting of a mechanical hinge embedded in the belt material or by means of the SK ("SelfKnot") system, a simple knot in the traction cable that ensures the required mechanical strength. In addition, special belt connectors have been developed for PolyChain belts and wide-tooth belts, for example.
Alphabelt - Your partner even for complicated installation situations
No matter what type of belt you want to use on your system and how complicated the installation situation appears - as a competent partner for individual special belts, we will be happy to advise you on which connection technology is best suited for your application. Just contact us, together we will find the best solution!
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