Continuous Crushing Tool for Excavator Bucket Fatigue
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Solution Overview
Problem
The existing crushing bucket designs with multiple welded components suffer from poor fatigue resistance due to stress concentrations at weld joints transverse to the shaft's longitudinal direction and weld terminations, which are prone to failure.
Innovation Solution
A continuous crushing tool extending along the entire shaft length replaces multiple weld joints with a single continuous weld, eliminating transverse welds and enhancing shaft strength by acting as both a crushing and load-bearing component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate welded components are used for crushing tools, then the structure allows modular assembly and replacement, but the fatigue resistance deteriorates due to stress concentrations at multiple weld joints and terminations
Solution Approach 1:
The patent merges multiple separate crushing tool components into a single continuous crushing tool that spans the entire shaft length. This eliminates the need for multiple weld joints and terminations, thereby removing stress concentration points while maintaining the modular benefit of a replaceable unit. The continuous tool is attached to the shaft via a single continuous weld, significantly improving fatigue resistance.
2Productivity
If multiple separate crushing components are welded to the shaft, then the crushing function is achieved, but the shaft strength deteriorates due to stress concentrations at transverse weld joints
Solution Approach 1:
The patent combines multiple separate crushing components into one continuous crushing tool that extends along the entire shaft length. This single component is welded to the shaft in one continuous operation, eliminating transverse weld joints that create stress concentrations. The result is a shaft that maintains its full strength while still achieving the required crushing function.
3Reliability
If a continuous crushing tool is used along the shaft length, then the fatigue resistance improves by eliminating multiple weld joints, but the device complexity increases due to the single long component
Solution Approach 1:
The patent integrates multiple crushing functions into a single continuous tool component that spans the entire shaft length. While this appears to increase complexity, it actually simplifies the overall structure by eliminating multiple separate components, weld joints, and terminations. The single component design reduces assembly complexity and improves reliability simultaneously.
Data Source
AI summary
The invention relates to a crushing bucket, which has been designed as an excavator or loader bucket. It comprises a bottom plate (1), side walls (2), and working drums (6) at a rear part of the bucket, which are rotatable about a shaft (6) thereof and crush, while rotating, a bucket-held material and at the same time deliver crushed material out of the bucket between or through the working drums (6). It also comprises enclosures (4) for the power transmission and bearing assemblies of the working drums (3), said enclosures being delimited by frame panels (4b) to which the working drums' (6) bearing cups are attachable. The working drum (6) is provided with at least one crushing tool (7), which is a continuous component extending substantially all the way along the length of a shaft (6a).