Adjustable Toggle Assembly for Crusher Force Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional toggle assemblies for crushing equipment are complex and expensive to maintain, require large and costly hydraulic cylinders, and involve fixed-length toggles and wedges, lacking adaptability and efficient force distribution, as well as needing complex programmable logic controllers and hydraulic power units.
Innovation Solution
An adjustable toggle assembly with a wedge and wear bars that can change length, using a hydraulic actuator to move between contracted and expanded positions, eliminating the need for large hydraulic cylinders and complex control systems, and allowing easy conversion between mechanical and hydraulic modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional toggle assemblies are used, then the structure is fixed and simple, but the maintenance cost is high and adaptability is poor
Solution Approach 1:
The toggle assembly incorporates adjustable-length toggles and wedges that can be modified in the field using field-weldable extensions. This dynamic adjustment capability allows the crusher setting and toggle length to be changed based on operational requirements, resolving the contradiction between adaptability and structural simplicity.
Solution Approach 2:
The toggle and wedge components are segmented into modular sections that can be independently adjusted or extended. This segmentation enables flexible length adjustments while maintaining the overall simplicity of the assembly structure, allowing maintenance personnel to modify only specific segments as needed.
2Force
If conventional hydraulic systems are used, then the crushing forces can be applied, but the hydraulic cylinders are large and expensive
Solution Approach 1:
The invention replaces conventional large hydraulic cylinders with a mechanically-driven toggle assembly system. The mechanical advantage provided by the toggle geometry enables efficient force multiplication and distribution, eliminating the need for oversized hydraulic components while maintaining effective crushing forces.
Solution Approach 2:
The system changes the operational parameters by using adjustable toggle lengths and wedge positions to optimize force distribution. This allows the mechanical system to achieve the same crushing effect as large hydraulic systems but with more compact and cost-effective components.
3Adaptability or versatility
If fixed-length toggles are used, then the assembly is simple, but the crusher setting cannot be changed
Solution Approach 1:
The toggle assembly transitions from fixed-length to dynamically adjustable length through field-weldable extensions. This allows the crusher setting to be changed by adding or removing toggle length segments, providing adaptability while maintaining manufacturing simplicity through standardized extension components.
Solution Approach 2:
Field-weldable extensions are pre-prepared and can be attached to the toggles when adjustment is needed. This preliminary preparation of extension components enables quick setting changes without complex manufacturing processes, balancing adaptability with ease of manufacture.
4Ease of repair
If conventional wear bar configurations are used, then the structure is simple, but the wear parts cannot be easily replaced
Solution Approach 1:
The wear bar assembly is segmented into modular sections with standardized interfaces. This segmentation allows individual wear bars to be easily removed and replaced without affecting the entire assembly, improving ease of repair while maintaining structural simplicity through repeated modular units.
Solution Approach 2:
The wear bar design incorporates universal mounting features that allow the same wear bar components to be used in multiple positions and configurations. This universality simplifies the overall structure while enabling easy replacement and interchangeability of wear parts across different assembly locations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adjustable toggle assembly reduces maintenance and replacement costs, enhances force distribution, and allows for adaptable crusher settings, eliminating the need for expensive hydraulic systems and complex control units, while enabling wear parts and flexible toggle lengths.
Implementation Method 1
a wedge (42) having a wedge top side, a wedge bottom side, and a generally tapered configuration
Implementation Method 2
using a hydraulic actuator to move between contracted and expanded positions
Implementation Method 3
a first wear bar (44) having a first wear bar top side, a first wear bar bottom side, and being configured to contact the wedge
Data Source
AI summary
An adjustable toggle assembly adapted for use on an item of crushing equipment having a frame and a jaw, said adjustable toggle assembly. The assembly includes a wedge having a generally tapered configuration, a first wear bar configured to contact the wedge, and a second wear bar configured to contact the wedge. The assembly also has a first cover plate and a second cover plate. The assembly further includes a means for moving the wedge relative to the first wear bar and the second wear bar. The assembly still further includes a first toggle seat that is connected to the frame and a second toggle seat that is connected to the jaw. The means for moving the wedge relative to the first wear bar and the second wear bar is adapted to move the wedge between a contracted position and an expanded position.