Custom belt solution improves safety and halves fitting time for piston ring manufacturer

A manufacturer of piston rings and sealing rings had traditionally used drive chain with clamps to wrap around finished piston rings and clamp them together after the manufacturing process. While effective, the method created two challenges:

1. The chain was extremely heavy and difficult to move around site. Repeated handling made the process physically demanding for engineers and raised clear health and safety concerns.
2. The chain took up significant storage space, especially for the larger piston ring sizes. Finding and maintaining enough space for storage was both difficult and costly.

When the manufacturer raised the issue with Business Development Manager, Jack Burge, it was clear that although the chain was doing the job, it was not the most practical long-term solution. The customer felt there were no other options. This is where ACORN were able to assist.

Jack detailed measurements worked with a specialist belt manufacturing partner to create a custom-made belt solution. The new belts were designed with a channel along the centre length of the belt to prevent the piston rings from moving axially during tightening. To solve the need to manufacture clamps, they also incorporated steel clamping elements to allow quick, secure fastening. The belts were manufactured to withstand the relative forces of tightening the piston rings to ensure it does not stretch and has a long lifespan to save unnecessary replacements.

Compared with the chain arrangement, the belts are significantly lighter and easier to handle, improving safety for engineers during fitting. They are also quicker to fit, reducing the time required for the task by around 50%.

Since implementation, the operators have been pleased with the reduced weight and improved handling. The belts have also proven capable of closing even the largest rings without deformation.

This project shows how ACORN can work with customers to challenge established methods and develop practical alternatives that improve safety, save time and make day-to-day operations easier.