Armored Mining Rope Shield for Abrasion and Fatigue
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Solution Overview
Problem
Existing surface mining ropes in electric rope shovels are prone to damage from debris and abrasion, particularly in the d-block area or padlock sheave area, leading to increased vibratory fatigue and accessibility issues.
Innovation Solution
The implementation of a protected surface mining or hoist rope with armoring shield segments made from materials like rubber, synthetic fiber, or poly fiber and carbon fiber, applied at high-impact zones such as the vertical portions adjacent to the d-block area, to provide enhanced abrasion resistance and vibration dampening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a thick metal pipe is used as a cover for the surface mining ropes, then abrasion resistance is improved, but the weight increases leading to increased vibratory fatigue
Solution Approach 1:
The patent applies a flexible polymer jacket (thin film) instead of a rigid metal pipe (thick shell) to protect the rope from abrasion. This flexible coating provides the necessary protection while being lightweight enough not to significantly increase the rope's weight or vibratory fatigue.
Solution Approach 2:
The patent uses composite material construction with the rope core surrounded by a polymer jacket layer. This composite structure combines the strength of the steel rope with the abrasion resistance of the polymer material, achieving protection without the excessive weight of solid metal piping.
2Object-affected harmful factors
If a metal pipe cover is bolted or clamped onto the ropes, then protection is improved, but the complexity of assembly and maintenance increases
Solution Approach 1:
The patent merges the protective function directly into the rope structure by applying a polymer jacket that is integral to the rope construction. This eliminates the need for separate protective components like metal pipes, bolts, or clamps, thereby simplifying both assembly and maintenance.
Solution Approach 2:
The flexible polymer jacket can be applied directly to the rope in a continuous process, creating a seamless protective layer that requires no additional fastening components. This thin film approach simplifies the overall structure compared to rigid metal pipe assemblies with multiple fasteners.
3Object-affected harmful factors
If a semi-permanent cover is applied to the ropes, then protection is improved, but accessibility for maintenance is worsened
Solution Approach 1:
The polymer jacket is designed with dynamic characteristics that allow it to flex and move with the rope during operation, providing continuous protection. When maintenance is needed, the jacket can be removed or adjusted without permanent attachment, maintaining accessibility while providing protection during use.
Solution Approach 2:
The flexible nature of the polymer jacket allows it to be easily removed, adjusted, or replaced without permanent installation. Unlike rigid metal covers that require bolting and unbolting, the flexible film can be slid off or cut away quickly for maintenance access.
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 armoring shield segments significantly prolong the life of the surface mining ropes by protecting them from abrasion and debris impact, while also reducing vibratory fatigue and maintaining accessibility for maintenance.
Implementation Method 1
The armoring shield segments significantly prolong the life of the surface mining ropes by protecting them from abrasion and debris impact, while also reducing vibratory fatigue
Implementation Method 2
The armoring shield segment may be comprised of an armoring jacket or material positioned around a base portion of the rope... constructed from natural or synthetic rubber, an elastomer
Implementation Method 3
The armoring shield segments may include an inner portion constructed from a rubberized material
Data Source
AI summary
A protected surface mining or hoist rope for an electric dipper shovel is provided. The protected surface mining or hoist rope can include a base rope portion and one or more armoring shield segments applied to the base rope portion. The armoring shield segments can be spaced apart along the length of the protected surface mining or hoist rope to provide additional protection at high-impact or abrasion areas of the rope.