Bucket Edge Wear Protector With Plug-Welded Split Members
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Solution Overview
Problem
Existing edge wear protector systems for buckets in earth-moving equipment are heavy, prone to frequent replacement, and difficult to fit all types of bucket joints, leading to increased maintenance and operational costs due to their larger size and lower hardness, which results in higher wear and digging resistance.
Innovation Solution
An edge wear protector system comprising a first member attachable to a bucket's base plate and a second member attachable to a side plate, with a plug channel and plug duct design allowing for secure plug welding, enabling a lighter and more durable solution that fits various bucket joint types by using dual materials with varying hardness levels for the upper and lower layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the wear protector is made larger to increase structural strength and lifespan, then the structural strength is improved, but the bucket weight increases and digging resistance increases
Solution Approach 1:
The wear protector is divided into two separate members: a first member attachable to the base plate and a second member attachable to the side plate. This segmentation allows each member to be optimized independently for strength and weight, providing the necessary structural protection without requiring a single large, heavy component.
Solution Approach 2:
The wear protector system uses dual materials with varying hardness levels for the upper and lower layers. The first member (attached to base plate) and second member (attached to side plate) can be made from different material compositions, allowing optimization of hardness and weight characteristics for each specific location and loading condition.
2Adaptability or versatility
If the wear protector is made larger to accommodate different bucket joint types, then the adaptability is improved, but the digging resistance increases
Solution Approach 1:
By separating the wear protector into two members that attach to different surfaces (base plate and side plate), the system can accommodate various joint configurations (H-type, N-type, T-type) without requiring a single oversized component. Each member can be sized appropriately for its specific attachment location.
Solution Approach 2:
The two-member system design provides universal applicability across different bucket joint types through flexible attachment configurations. The first member attaches to the base plate and the second member attaches to the side plate, allowing the same basic design to work with various joint geometries without increasing overall size.
3Ease of manufacture
If the wear protector is made from low cost abrasion resistant cast steels, then the manufacturing cost is reduced, but the wear resistance decreases due to lower hardness
Solution Approach 1:
The wear protector employs dual materials with varying hardness levels distributed across the upper and lower layers of the first and second members. This allows harder, more wear-resistant materials to be used in high-wear areas while maintaining cost-effectiveness in less critical areas, optimizing both reliability and manufacturing cost.
Solution Approach 2:
Different regions of the wear protector members are made from materials with different hardness characteristics. The dual-material construction allows local optimization where higher hardness is applied to surfaces experiencing the most abrasion, while other areas use more cost-effective materials.
4Device complexity
If a single type of wear protector is used to fit all bucket joint types, then the device complexity is reduced, but the fit and structural strength are compromised
Solution Approach 1:
The wear protector is divided into two members with specific attachment functions: the first member for the base plate and the second member for the side plate. This segmentation creates a standardized design that can be universally applied while maintaining proper fit and structural strength for different joint types.
Solution Approach 2:
The two-member system provides a universal solution that maintains consistent structural strength across different bucket joint configurations. The standardized attachment methodology (plug welding to base plate and side plate) ensures reliable performance without requiring custom designs for each joint type.
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 system provides enhanced structural strength, reduced weight, and extended lifespan by allowing internal welding and dual material usage, minimizing fatigue and friction, while accommodating different bucket joint configurations, thus reducing maintenance and operational costs.
Implementation Method 1
a plug channel and plug duct design allowing for secure plug welding
Data Source
Figure 1~2B
Figure 3A~4
Figure 5~6B
AI summary
The present invention provides an edge wear protector system adapted to be attached to a bucket of earth moving equipment, the bucket includes a base plate and a side plate connected to the base plate. The edge wear protector system includes a first member attachable to the base plate. First member includes an attaching side adapted to connect to the base plate when the first member is attached to the base plate, such that the first member includes a plug channel adapted to receive a plug weld therein and the plug channel is disposed on the attaching side of the first member. The edge wear protector includes a second member attachable to the side plate. Second member includes an attaching side adapted to connect to the side plate when the second member is attached to the side plate, such that the second member includes a plug channel adapted to receive a plug weld therein and the plug channel is disposed on the attaching side of the second member; and such that the first member is connectable to the second member.