Cable Pulley Spokes Using Bent Flat Material
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Solution Overview
Problem
Conventional rope sheaves in the mining sector face challenges with the weldability and accessibility of rolled profile spokes, leading to increased production costs and potential material connection quality issues due to non-homogeneous material and complex geometry.
Innovation Solution
The use of single, flat material spokes bent over the cross-section, preferably with an S, Z, or W-shaped waveform, simplifies assembly and connection by providing easier access and a more uniform material thickness, allowing for effective welding and reducing weight through a central recess, thus improving the connection quality and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rolled profiles are used as spoke material, then the spokes have sufficient strength and stability, but the material is not homogeneous which negatively influences weldability and connection quality
Solution Approach 1:
The patent applies the homogeneity principle by using uniformly thick flat material (sheet metal or plate) for the spokes instead of rolled profiles. This ensures consistent material properties throughout the spoke, enabling homogeneous welding and high-quality connections to both the hub and rim, directly resolving the weldability and connection quality issues mentioned in the problem statement.
2Stability of the object's composition
If rolled profiles are used as spokes, then the structural stability is maintained, but the weld points are difficult to reach due to geometry which increases production cost
Solution Approach 1:
The patent applies curvature by forming the flat material into corrugated or wavy profiles (S-shaped, Z-shaped, or W-shaped cross-sections) instead of using straight rolled profiles. This curved geometry provides structural stability comparable to traditional profiles while creating accessible surfaces for welding, allowing weld points to be easily reached from multiple directions and significantly reducing production costs.
3Stability of the object's composition
If conventional rolled profile spokes are used, then the sheave has necessary stability, but the complex geometry makes machining for required surface quality difficult and costly
Solution Approach 1:
The patent applies parameter changes by modifying the cross-sectional geometry parameters of the spokes. Instead of using standard rolled profile dimensions, the flat material is formed into specific corrugated profiles with optimized wave patterns (S, Z, or W shapes). These parameter changes achieve the required structural stability and surface quality while simplifying the manufacturing process and reducing machining costs.
4Manufacturing precision
If U-shaped sheets connected at the back are used instead of rolled sections, then the material connection is improved, but the weld seam accessibility remains difficult when designed as full connection
Solution Approach 1:
The patent applies segmentation by dividing the connection interface into multiple accessible surfaces through the corrugated profile design. The S-shaped, Z-shaped, or W-shaped cross-sections create multiple welding surfaces that can be accessed from different directions, effectively segmenting the connection process into manageable stages and eliminating the accessibility problems of full connections while maintaining high connection quality.
Data Source
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AI summary
The invention relates to a cable pulley for use as a guide device between a conveying means and a cable carrier, comprising a cable pulley ring, a hub (4) and cable pulley spokes (6) connecting the cable pulley ring and hub, wherein the cable pulley spokes (6) are each formed from a single trapezoidal flat material bent multiple times over the cross-section of the cable pulley spoke (6), the wide base of which is arranged on the hub (4).