Composite Transverse Bar Lining for Low-Abrasion Energy Chains
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Solution Overview
Problem
Existing energy guiding chains cause abrasion and wear on guided lines, particularly in direction-changing arcs, due to friction against the transverse bars, and existing solutions either complicate the structure or reduce internal space for line guidance.
Innovation Solution
A transverse bar with a line-protecting layer made of a second plastic, different from the main body, that covers the inside of the main body between the narrow sides to reduce abrasion and friction, while keeping the holding devices accessible for connecting separating bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the transverse bar is made from fibre-reinforced plastic of considerable hardness, then the structural strength and stability of the chain link is improved, but the abrasion and wear of the guided lines increases due to friction in the direction-changing arc
Solution Approach 1:
The transverse bar features a line-protecting layer made of a softer second plastic that covers only the inside surface of the main body between the narrow sides, while the holding devices at the narrow sides remain uncovered. This local differentiation allows the bar to maintain structural strength from the hard first plastic while providing abrasion protection only where lines contact the bar.
Solution Approach 2:
The transverse bar combines two different plastics: a hard fibre-reinforced first plastic for the main body providing structural strength, and a softer second plastic for the line-protecting layer that reduces friction and abrasion on guided lines. This composite structure resolves the contradiction between strength and abrasion resistance.
2Object-affected harmful factors
If the inside surfaces of chain links are coated with an anti-friction lacquer, then the abrasion of guided lines is reduced, but the manufacturing complexity and labor requirements increase
Solution Approach 1:
Instead of applying a coating process, the invention uses a composite material structure where the line-protecting layer is integrated as a separate plastic material molded onto the main body. This eliminates the need for post-manufacturing coating processes while achieving the same abrasion reduction effect.
Solution Approach 2:
The line-protecting layer is pre-formed and integrated into the transverse bar structure during manufacturing, rather than being applied as a separate coating step after the main body is produced. This preliminary integration simplifies the overall manufacturing process.
3Object-affected harmful factors
If separate elastically deformable tube elements are mounted rotatably to the transverse bars, then the wear of guided lines is reduced, but the internal space available for line guidance is significantly reduced
Solution Approach 1:
The line-protecting layer is formed as a thin film or shell that conforms to the inside surface of the transverse bar between the narrow sides. This thin protective layer provides abrasion resistance while occupying minimal space, unlike bulky tube elements.
Solution Approach 2:
The line-protecting layer is applied only where necessary - specifically on the inside surface between the narrow sides where lines contact the bar - rather than covering the entire transverse bar. This partial application protects lines while preserving internal space.
4Object-affected harmful factors
If the line-protecting layer covers the entire inside surface of the main body, then the abrasion protection is maximized, but the holding devices for separating bars become inaccessible
Solution Approach 1:
The line-protecting layer is selectively applied only to the inside surface between the narrow sides, deliberately leaving the holding devices at the narrow sides uncovered and accessible. This local differentiation ensures both abrasion protection where needed and accessibility of functional features.
Solution Approach 2:
The line-protecting layer covers only the necessary area for abrasion protection (the inside surface between narrow sides) rather than the entire inside surface, leaving the holding devices exposed and accessible for their intended function.
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 solution effectively reduces abrasion and wear on guided lines by minimizing sliding friction, while maintaining compatibility with existing designs and allowing flexible internal division of the chain links.
Implementation Method 1
the plastic of the line-protecting layer, in particular in regard to the coefficient of friction, has a lower coefficient of friction than the plastic of the main body
Implementation Method 2
contact with edges of the plate-like main body of a transverse bar can result in abrasion and wear of the lines being guided
Data Source
AI summary
A transverse bar for a chain link of an energy guiding chain for guiding lines. The transverse bar has an elongate main body comprising a first plastic and at both longitudinal ends a connecting region for connection to the side plates. The main body of the transverse bar has two long narrow sides which each have a holding device for separating bars. Provided on the inside of the main body that faces towards the lines is a line-protecting layer for handling the lines gently and comprising a second plastic which is different from the plastic of the main body and is selected to reduce abrasion upon relative movement between a line and the transverse bar. In that case the line-protecting layer extends from one narrow side to the other and at least predominantly covers over the inside of the main body but leaves uncovered the respective holding device at the one narrow side and at the other narrow side.