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Ammeraal Endless Joint
Ammeraal Endless Joint
Ammeraal Endless Joint
What to do about failed endless joints
TM / 7.2.04
Wedge skive or finger joint
Claim Issue:
Endless joint failed
Finger joint
Skive or
See page 5
finger joint?
Skive
Check
endless joining
instructions
TM / 7.2.04 1
Wedge skive
Page 1
Shorter skive length
shorter
Measure results in a weaker joint due
skive length to the small PA-surface.
Refer to page 7+8
okay
Not matching of the skived PA-foil
Skived areas of wrong areas results in a weak joint due
PA-foil on both to the reduced contact surface
ends to match of PA-foil !
precisely Refer to page 9+10
okay
TM / 7.2.04 2
Wedge skive
Page 2
narrower Belt is narrower than originally
Measure
fabricated: Belt was running off!
belt width
Check application!
okay
yes Belts have limited resistant to many
Belt is dirty,
chemicals and solvents.
oily , greasy
Check application!
no
TM / 7.2.04 3
Wedge skive
Page 3
yes
10 mm break at Grinding process may not be perfect
the endless joint? Refer to page 11 - 14
no
yes
Joint breaks along
Refer to page15+16
its geometry
no Now, it is time to contact
the RAPPLON® manufacturers
TM / 7.2.04 4
Quick Splice finger joint
Page 1
Undefined design Use originally RAPPLON fingers
Check
30/50/110 mm
finger design
Refer to page 17
Original RAPPLON finger
Shorter than recommended in
Measure endless instruction It is important to use the right finger
finger length length to get enough contact surface
okay
TM / 7.2.04 5
Quick Splice finger joint
Page 5
While heating, thermoplastic is getting
Check thinner than material liquid like water. The width of belt and
thickness over guide rail have to match, otherwise
joint thermoplastic material flows off.
Refer to page 18 - 20
okay
Yes
Belt too weak for application or
Joint breaks across
not joining in the middle
the width
Refer to page 21+22
No Now, it is time to contact
the RAPPLON® manufacturers
TM / 7.2.04 6
Wedge skive – wrong wedge
This joint was made with the
wrong wedge. The skive
length is only 55 mm instead
of 72 mm.
(Indicated splice lengths just
as an example)
TM / 7.2.04 7
Wedge skive – wrong wedge
This joint was made with
wedge 3,4 instead of 2,4.
The difference is obvious!
(55 mm instead of 72 mm)
(Indicated wedge no. and
skive lengths just as an
example)
TM / 7.2.04 8
PA-foil area
Joint failure of GG 06/R20 after a short time
Zone 1
Zone 1has definitely not
has definitely not
bonded properly as 2 different
bonded properly as 2 different
materials and glues were
materials and glues were
mixed. This has caused the
mixed. This has caused the
opening of the joint after a
opening of the joint after a
short running time.
short running time.
TM / 7.2.04 9
PA-foil area
Zone X (Polyamide foil) must match
Zone X (Polyamide foil) must match
x
together when inserting the belt into
together when inserting the belt into
the press!
the press!
Observe exactly matching placement
Observe exactly matching placement
of PA portion. If you only place or
of PA portion. If you only place or
match the ends of the rubber areas
match the ends of the rubber areas
could this result in a substantial
could this result in a substantial
reduction of PA-PA contact and will
reduction of PA-PA contact and will
consequently reduce the strength of
consequently reduce the strength of
the joint. This may create a joint
the joint. This may create a joint
failure after a short running time on
failure after a short running time on
the application.
the application.
The bigger the displacement, the
The bigger the displacement, the
more it creates a potential breaking
more it creates a potential breaking
section (no adhesion on the zone
section (no adhesion on the zone
where material and glue is mixed).
where material and glue is mixed).
x
TM / 7.2.04 10
10 mm break at the endless joint
Cracks at the endless joint
approx. 10 mm
PA- Delamination starts at the endless joint
approx. 10 mm
TM / 7.2.04 11
10 mm break at the endless joint
Grinding Why does this happen?
machine Because the grinding process was not perfect!
Grinding direction
Rubber
PA-Foil
Rubber
approx. 10 mm approx. 10 mm
TM / 7.2.04 12
10 mm break at the endless joint
X =
Heating process
Already after the
heating process you
can find crackings a
approx. 10 mm
few mm after the
endless joint.
X
approx. 10 mm
TM / 7.2.04 13
10 mm break at the endless joint
No
What to do?
Final skiving!
Without any further adjustment
of the grinding machine.
Just move grinding roll with the
Yes same final setting over the endless
joint and remove any unevenness.
Rubber
PA-Foil
Rubber
TM / 7.2.04 14
Joint breaks along its geometry
There are several possibilities which can cause this failure. Please be sure, that
your process is error-free by using these checkpoints:
Temperature and/or heating time not correct
•Check the temperature of your press by using the thermometer
•Please keep in mind, the recommended pressing time on our instruction
sheets is valid for heated presses.
•Double the heating time with single side heated presses.
Skive surface contaminated
•Change the sandpaper of your skiving equipment regularly
•Keep the polyamide surface always clean, don’t touch it!
Wrong or old glue
Glues have a limited durability! New bottles have to be stored in a dry and
cool place! Bottles once opened have to be used in the next few days.
Marking the bottle with the opening date is helpful. After using always close
the bottle immediately and properly.
TM / 7.2.04 15
Joint breaks along its geometry
Not often, but it happens:
The joint above left looks nice but in
fact only B600 is added. Glue 118 N
is completely missing.
The same joint after tensioning.
Note the rough surface of the
polyamide - no 118 N was applied.
TM / 7.2.04 16
Finger design
Never do things like this!
This example is a longitudinal joint
geometry for conveyor belts, found in a
GG 4E RF an endless joint.
Use original equipment and you
will produce good quality.
TM / 7.2.04 17
Guide rail wider than belt
While heating, thermoplastic is
getting liquid. The width of belt and
guide rail have to match, otherwise
thermoplastic material flows off at
the edges.
In this case a GG 5/50 RR is shown
which has a very thick thermoplastic
foil so that the fingers still melted
together. On types with thin
thermoplastic layers like TG E4 RQ,
there is no chance to join the belt, if
you loose material at the edges.
TM / 7.2.04 18
Joint too thin
The thin red line indicates the joint
3 mm 2,2 mm (finger length). In this area, the
thickness is 2,2 mm instead of the
original thickness of 3 mm.
TM / 7.2.04 19
Joint too thin
The same joint from top view. There is
almost no thermoplastic material left
between the fingers (red arrow).
In the circled area, the belt is 4 mm
thick, now you can can imagine, to
where the thermo-plastic flowed.
This joint was definitively not made
with RAPPLON®-equipment. It seems,
that there was only pressure applied
over the finger length and maybe also
too much pressure.
TM / 7.2.04 20
Joint breaks across the width
The heating plates of the QSP 60
are 60 mm wide. These 50 mm
fingers shown on the left were
not placed in the middle of the
guide rail. Therefore the
fingertips are not completely
melted together.
This joint failed within minutes.
TM / 7.2.04 21
Joint breaks across the width
There are several possibilities which can cause this
failure:
1. Type is too weak for this application. Ask
customer for required specifications.
2. Maybe torsion in application (shearing forces).
3. Working tension too high
4. High sudden load (start up, jam)
TM / 7.2.04 22
Conclusion
Endless making is a very important fabricating process which is carried out at
RAPPLON’s distribution partners (OC, distributor).
The quality of the endless joint influences the performance of any fabricated belt
substantially.
Should there occur any quality issues on the endless making, we strongly
recommend to check this subject by using this decision matrix!
You have the know-how about your local fabricating process as well as the
knowledge of the application where the belt is running.
This will already answer many question and will help your workshop and sales to
constantly improve the knowledge on the RAPPLON® range!
TM / 7.2.04 23