Chain Link Press-Fit Assembly Eliminates Welding
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Solution Overview
Problem
The existing methods for manufacturing dragline bucket chains are time-consuming, labor-intensive, and costly due to the need for welding and lengthy heat treatment processes, which can result in defects and inadequate durability.
Innovation Solution
A chain assembly method using a two-piece link subassembly with a press-fit design, where a main link member and a press-in link member are interlocked, eliminating the need for welding and allowing for individual component heat treatment and assembly, reducing production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chains are cast as one assembly, then manufacturing continuity is improved, but production time and heat treatment complexity increase
Solution Approach 1:
The chain is divided into separate cast links that are assembled together through pressing and welding operations. This segmentation allows individual links to be manufactured independently and then joined, resolving the contradiction by enabling parallel production while maintaining assembly continuity.
2Stability of the object's composition
If weld-in sections are used to join links, then link connectivity is improved, but welding time and labor intensity increase
Solution Approach 1:
The press-fit sections are pre-formed during the casting process itself, so that when links are assembled, the pressing operation simply seats the pre-formed sections into place. This preliminary preparation eliminates the need for complex welding procedures, maintaining link connectivity while dramatically reducing assembly time and labor.
3Strength
If the entire chain is heat treated, then material strength is improved, but equipment length and space requirements increase
Solution Approach 1:
Heat treatment is applied to individual links or small groups of links rather than the entire chain assembly. This segmentation of the heat treatment process allows using shorter, more compact equipment while still achieving the required material strength properties in each link.
4Strength
If welding is used to attach press-out sections, then joint strength is improved, but welding precision requirements and scrap risk increase
Solution Approach 1:
The press-fit section acts as an intermediary element between links. It is designed with geometric features that guide precise alignment during pressing, and its shape is optimized to distribute weld loads evenly. This intermediary design reduces the precision demands on welding operations while maintaining joint strength.
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
This approach significantly reduces production time and costs, enhances durability by eliminating welding, and allows for final heat treatment before assembly, resulting in a more robust and efficient chain assembly process.
Implementation Method 1
The corresponding interlocking features of both members define a plurality of surfaces and at least two of those surfaces are configured to create an interference with each other during a pressing operation
Implementation Method 2
The method may further comprise cooling or heating one link member before completing the pressing operation
Data Source
AI summary
A method of forming a chain having a plurality of links that are formed from separate link members is provided that includes press fitting one link member into another link member. The method may further comprise cooling or heating one link member before completing the pressing operation.