Auto-fill Two-layer Wear-resistant Elbow for Concrete Pumps
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Solution Overview
Problem
Current wear-resistant elbows for concrete pump trucks face issues of high cost, poor wear resistance, and safety concerns due to single-layer designs or complex manufacturing processes, with existing solutions either wasting materials or increasing costs without effectively extending service life.
Innovation Solution
A two-layer, two-half wear-resistant elbow design featuring an outer protection layer and an inner heterogeneous wear-resistant combined layer with a filling reinforcement bay, where the inner layers are made of different materials to enhance wear resistance and auto-fill during initial use, reducing friction and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single-layer high manganese steel elbows are used, then the cost is low and manufacturing is simple, but the wear resistance and hardness are poor
Solution Approach 1:
The patent applies composite materials by combining high manganese steel outer layer with high chromium cast iron inner layer. The outer layer provides structural strength and toughness, while the inner layer provides superior wear resistance. This composite structure resolves the contradiction by achieving both reasonable manufacturing complexity and excellent wear resistance properties.
Solution Approach 2:
The patent applies local quality by making different parts of the elbow have different material properties. The inner layer uses high chromium cast iron specifically at wear-prone areas, while the outer layer uses high manganese steel for structural support. This localized material differentiation achieves superior wear resistance without unnecessarily increasing overall manufacturing complexity.
2Reliability
If double-layer high chromium cast iron elbows are used, then the wear resistance and hardness are excellent, but the cost is high and performance-to-price ratio is low
Solution Approach 1:
The patent applies local quality by using high chromium cast iron only in the inner layer where wear resistance is most needed, rather than making the entire elbow structure from expensive high chromium cast iron. The outer layer uses more cost-effective high manganese steel, achieving excellent wear resistance at a lower overall cost.
Solution Approach 2:
The patent applies composite materials by strategically combining expensive high chromium cast iron with more economical high manganese steel. This composite approach achieves the wear resistance of double-layer high chromium elbows while reducing material costs through selective material placement.
3Reliability
If high molecular elastomer layer is added to wear resistant elbow, then wear resistance is improved, but the cost increases and the probability of peeling under fluid washing increases
Solution Approach 1:
The patent applies composite materials by using high chromium cast iron inner layer combined with high manganese steel outer layer, both of which are metallurgically compatible and can be cast together. This metallic composite structure eliminates the peeling problem associated with elastomer layers while maintaining superior wear resistance and avoiding additional manufacturing costs.
4Reliability
If inner wall is formed by providing and filling a recess on the arc-shaped inner surface, then wear resistance at recess position is improved, but the manufacturing complexity increases and mounting fastness problems occur
Solution Approach 1:
The patent applies composite materials by creating a two-layer structure where the inner layer of high chromium cast iron is cast conformally against the outer layer of high manganese steel. This eliminates the need for separate recess formation and filling operations, reducing manufacturing complexity while providing uniform wear resistance throughout the inner surface.
Data Source
AI summary
An auto-fill two-layer two-half wear resistant elbow of a concrete pump truck consists of an outer-layer protection elbow, an inner-layer heterogeneous wear resistant combined elbow and a wear resistant connecting flange. A filling space is provided between the outer-layer protection elbow and the inner-layer heterogeneous wear resistant combined elbow. The wear resistant elbow is designed as a two-layer two-half unique structure including a protection layer and a wear resistant layer. Upon using the wear resistant elbow for the first time, the concrete grout fills the reserved slit via the heterogenous combined elbow and enters the reserved filling space, allowing the outer-layer protection elbow and the inner-layer heterogeneous wear resistant combined elbow to be fixed as a whole.