Interlocking Dumper Floor Panels to Prevent Cracks and Load Adhesion
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Solution Overview
Problem
The existing floor construction of aluminum box type dumper trucks experiences issues such as cracks, plastic deformations, and adherence of loads due to improper welding, leading to imbalance, increased fuel consumption, and difficulty in load discharge, especially under overloading conditions. Additionally, the design makes repair and maintenance challenging and increases labor costs.
Innovation Solution
The integration of interlocking floor panel profiles that eliminate the need for welding, providing central reinforcement to prevent deformations, adherence, and facilitating easy maintenance by using a closed-section floor panel cross design with elastic wedges for impact damping, ensuring geometric bearing and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding method is used to join floor reinforcement crosses to floor sheet, then structural strength is improved, but cracks and plastic deformations occur under overloading conditions
Solution Approach 1:
The floor structure is divided into modular floor panels with integrated reinforcement crosses, where each panel is a self-contained unit. This segmentation allows the reinforcement to be inherently part of the panel structure rather than separately welded, eliminating welding-related cracks while maintaining structural integrity through the modular design.
Solution Approach 2:
The floor reinforcement crosses are merged with the floor sheet to form an integrated floor panel structure. The reinforcement crosses are positioned within recesses of the floor panel and secured through mechanical interlocking rather than welding, combining the structural support function with the floor surface into a unified component that resists cracking.
2Strength
If welding method is used to join floor reinforcement crosses to floor sheet, then structural strength is improved, but weld shrinkages and faux pas occur due to long distance between reinforcement and floor sheet
Solution Approach 1:
The reinforcement crosses are pre-positioned within recesses of the floor panel during manufacturing, establishing the correct geometry and position before final assembly. This preliminary positioning ensures that the reinforcement is optimally located to provide structural support without creating weld shrinkage distortions, as the mechanical interlocking system accommodates precise positioning without the thermal distortion issues of welding.
3Ease of manufacture
If floor reinforcement crosses have open V or U shape sections, then manufacturing is simplified, but cross deformation occurs due to bevel ends between two welding methods
Solution Approach 1:
Instead of using open V or U shapes that require beveled ends for welding, the invention inverts the approach by using closed-section reinforcement crosses that are mechanically interlocked. This inversion eliminates the need for beveling and welding-related deformation, as the closed section geometry provides inherent structural stability and the mechanical connection system accommodates the shape without causing distortion.
4Strength
If elastic wedge is affixed to lower section of floor reinforcement crosses with adhesive, then impact damping is provided, but wedge detachment occurs over time
Solution Approach 1:
The adhesive bonding system is replaced with a mechanical interlocking system. The elastic wedges are secured through geometric bearing and mechanical engagement features integrated into the floor panel structure, providing both impact damping and stable attachment. This mechanical system eliminates the detachment issue inherent in adhesive bonding while maintaining the energy-absorbing function of the elastic material.
5Weight of moving object
If floor sheet thickness is reduced to 6 mm to decrease vehicle weight, then fuel consumption is reduced, but floor strength and resistance are insufficient
Solution Approach 1:
The floor structure uses a composite design combining a thin 6 mm floor sheet with integrated reinforcement crosses made of high-strength material. The reinforcement crosses are positioned within recesses of the floor panel, creating a composite structure where the thin sheet provides the floor surface while the reinforcement crosses provide the necessary structural strength, achieving both weight reduction and strength requirements.
6Measurement precision
If floor reinforcement crosses are pre-installed and welded after positioning to ensure measurement accuracy, then positioning precision is improved, but installation time and labor costs increase
Solution Approach 1:
The floor structure is segmented into complete floor panels that are pre-assembled in manufacturing with reinforcement crosses already integrated in their final positions. This segmentation allows precise positioning to be achieved during manufacturing rather than during field installation, reducing on-site installation time while maintaining measurement accuracy through the modular panel design.
Solution Approach 2:
The reinforcement crosses are pre-positioned and integrated into the floor panel structure during manufacturing, performing the positioning action in advance. This preliminary action ensures measurement accuracy is achieved during controlled manufacturing conditions rather than during field installation, significantly reducing installation time and labor costs while maintaining precise geometric bearing.
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 solution enhances the structural endurance and smoothness of the floor, prevents load adherence, reduces fuel consumption, and simplifies maintenance by eliminating the need for additional repairs, thereby improving the overall performance and efficiency of the dumper trucks.
Implementation Method 1
an elastic wedge is affixed to the lower section of the floor reinforcement crosses so that it is located between the chassis and the basin
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a floor embodiment (A), which is positioned on the dumper chassis (20) in the box type dumper trucks (1), and forms the floor of the dumper vessel (10) where the load to be transported is stored; and connected with the elastic wedge (50) placed on mentioned dumper chassis (20), and absorbs the vibrations to be transmitted to the dumper vessel (10), the solid floor panel (30), which is extended crosswise on said dumper vessel (10) ground, and having been positioned and combined side by side throughout all the floor, forms the floor embodiment of the dumper vessel (10); and the floor profile (40), which interconnects mentioned floor panels (30) and by connecting it with the elastic wedge (50), positioned on the dumper chassis (20).