Self-unloading Conveyor Chain Bar Design
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Solution Overview
Problem
Conventional chain bars for self-unloading bulk material conveyors are heavy, prone to wear, and can damage the floor liner, leading to increased energy consumption and reduced conveyor life.
Innovation Solution
A lightweight, strong chain bar with a rounded profile and broad, flat feet for smooth sliding, made from Domex XF AS Rolled Extra High Strength Cold Forming Steel, which can be easily bent and assembled without welding, providing substantial bearing surfaces and easy access for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional chain bars are used, then the conveyor system is structurally sound, but the chain bars are heavy and cause increased energy consumption
Solution Approach 1:
The chain bar design changes the geometric parameters by introducing a rounded profile with broad flat feet, optimizing the distribution of material to reduce weight while maintaining structural integrity and bearing capacity
Solution Approach 2:
The patent specifies using Domex XF AS Rolled Extra High Strength Cold Forming Steel, which is a high-strength steel material that provides superior strength-to-weight ratio, allowing the chain bar to be lighter while maintaining structural soundness
2Reliability
If conventional chain bars are used, then the conveyor provides sufficient friction, but the chain bars wear and damage the floor liner
Solution Approach 1:
The chain bar features a rounded profile with broad flat feet instead of sharp edges, which distributes contact pressure more evenly across the floor liner surface, reducing stress concentration and preventing liner damage while maintaining sufficient friction for conveyor operation
Solution Approach 2:
The broad flat feet are specifically designed at the contact points with the floor liner to provide substantial bearing surfaces, concentrating the wear resistance where it is most needed while keeping the rest of the chain bar lighter
3Ease of manufacture
If conventional chain bars are used, then the conveyor structure is stable, but the chain bars are difficult to assemble
Solution Approach 1:
The chain bar is designed as a separate component that can be manufactured independently and then assembled into the conveyor system, with the rounded profile and flat feet facilitating easier handling and installation while maintaining structural stability through proper geometric design
Data Source
AI summary
A self-unloading bed includes a conveyor with chain bars that are strong, light-weight and non-damaging to the floor upon which the conveyor slides. The preferred chain bar is an elongated bar with two legs, each of said two legs having a foot. The feet extend away from the leading (unloading) direction, the transition from leg to foot being formed by smooth bends, so that no sharp edges exist that would gouge into the floor as the chain bar moves across the floor. The preferred chain bar, made of a single metal bar with four longitudinal bends, is extremely strong for its weight, and it unlikely to bend or gouge into the floor during use.