Flexible Hopper for Conveyor Misalignment Compensation
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Solution Overview
Problem
Existing conveyor systems for cold planers face issues with misalignment and varying material transfer amounts, leading to material loss during the transfer from the first conveyor to the second conveyor, which affects efficient rehabilitation of asphalt roadways.
Innovation Solution
A flexible hopper system is integrated into the conveyor system, featuring a flexible frame and skirt that can expand or contract to form an enclosure between the discharge end of the first conveyor and the charge end of the second conveyor, ensuring consistent material transfer and alignment adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid transfer housing and reception housing are used, then structural stability is improved, but adaptability to misalignment and varying material amounts deteriorates
Solution Approach 1:
The patent applies the dynamics principle by making the hopper flexible rather than rigid. The flexible hopper can dynamically adjust its shape and position to accommodate misalignment between conveyors and varying material amounts, while still providing structural support through its flexible construction.
Solution Approach 2:
The patent applies parameter changes by allowing the hopper's physical parameters (shape, volume, position) to change in response to operational conditions. The flexible hopper can expand or contract, shift position, and alter its configuration to maintain effective material transfer despite misalignment or varying material flow.
2Loss of substance
If a fixed enclosure is used, then material containment is improved, but flexibility in alignment adjustment deteriorates
Solution Approach 1:
The flexible hopper dynamically adjusts its enclosure properties while maintaining material containment. It can flex and move to accommodate alignment variations while still effectively containing and directing material from the first conveyor to the second conveyor.
Solution Approach 2:
The patent directly applies this principle by using a flexible hopper constructed from flexible materials that can form an enclosure. This flexible enclosure maintains material containment while allowing the hopper to adjust its shape and position for alignment compensation.
3Stability of the object's composition
If the second conveyor is fixed in position, then structural stability is improved, but ability to compensate for misalignment deteriorates
Solution Approach 1:
The flexible hopper provides dynamic compensation for misalignment between the first and second conveyors. Even when the second conveyor is fixed, the hopper can flex, expand, contract, and shift position to bridge the gap caused by misalignment and ensure continuous material transfer.
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 flexible hopper system effectively captures and transfers varying amounts of material, preventing loss and enabling continuous operation of the cold planer, reducing maintenance costs and operational disruptions.
Implementation Method 1
a flexible skirt attached to the flexible frame and configured to form an enclosure between the first discharge end and the second charge end
Data Source
AI summary
Some examples described herein include a flexible hopper for a conveyor system. The flexible hopper may include a hopper weldment attached to a frame of the conveyor, wherein the hopper weldment surrounds a charge end of the conveyor, a flexible frame configured to enable an opening of the flexible hopper to expand or contract, and/or a skirt attached to the flexible frame and configured to form an enclosure between the flexible frame and the hopper weldment.