Integrally Cast Bucket Hinge Assembly for Weld Joint Fatigue
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Solution Overview
Problem
Excavator buckets face failures due to fatigue stress at welded joints in the hinge assembly, leading to costly repairs and productivity losses, as they are subjected to extreme loads and wear during operations.
Innovation Solution
An integrally cast hinge assembly is developed, featuring a first and second hinge plate with a torque tube portion in between, where the hinge plates are weldlessly connected to the torque tube, providing a stronger and more durable structure compared to conventional welded designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If buckets are made from welded-together pieces, then manufacturing complexity is reduced and ease of manufacture is improved, but the welded joints become areas where cracks and failures due to fatigue stress occur, worsening reliability
Solution Approach 1:
The patent merges multiple separate components (hinge plates, torque tube, reinforcement plates) into a single integrally cast hinge assembly. This eliminates the welded joints between these components that were previously prone to fatigue cracks and failures, while still allowing the assembly to be manufactured as a complete unit through casting processes
2Device complexity
If welded joints are used in the hinge assembly, then device complexity is reduced and manufacturing is simplified, but the welded joints create stress concentrations that lead to cracks and failures under extreme loads, worsening strength
Solution Approach 1:
The hinge assembly components are merged into an integral structure through casting, eliminating welded joints that created stress concentrations. The monolithic structure distributes stresses more evenly throughout the assembly, preventing crack initiation and propagation at joint locations while maintaining structural strength under extreme loads
3Ease of manufacture
If conventional welded hinge assemblies are used, then manufacturing cost is reduced and ease of manufacture is improved, but the welded joints are prone to fatigue failures under extreme loads and wear, worsening durability
Solution Approach 1:
The patent combines multiple hinge assembly components into an integrally cast unit, eliminating welded joints that were susceptible to fatigue failures from extreme loads and wear. This integral structure significantly improves durability and service life while remaining manufacturable through established casting processes
Data Source
AI summary
An integrally cast hinge assembly for a bucket, including a first hinge plate, a second hinge plate spaced apart from the first hinge plate, and a torque tube portion extending between the first hinge plate and the second hinge plate, wherein the first hinge plate is weldlessly connected to the torque tube portion and the second hinge plate is weldlessly connected to the torque tube portion.