Galle Chain Maintenance Envelope for Safe Cleaning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing maintenance methods for Galle chains, used in hydraulic openings like lift gates, are hazardous for operators due to toxic cleaning and lubricating products and result in environmental harm, with limited effectiveness and the need for multiple sets for different pipe diameters.
Innovation Solution
An assembly with guide means, projection members, an envelope to retain products, sealing members, and adjustable mechanisms to adapt to varying geometries, allowing for automated cleaning and lubrication without product dispersion, using oscillatory mechanisms and on-board product reservoirs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning and lubrication methods are used with spray lances, then maintenance operations can be performed, but operator safety is compromised due to toxic products and high working heights
Solution Approach 1:
The maintenance system is segmented into distinct functional modules: cleaning device, lubrication device, and containment envelope. This segmentation allows each component to be optimized independently and enables automated operation that eliminates operator exposure to toxic substances while maintaining effective maintenance capabilities
Solution Approach 2:
The system enables self-service maintenance through automated cleaning and lubrication mechanisms that operate without direct operator contact with the Galle chain or toxic products. The automated envelope system contains and recycles maintenance products, making the system self-sufficient and eliminating the need for operators to work at hazardous heights
2Reliability
If traditional spray lance methods are used for maintenance, then cleaning and lubrication can be applied, but environmental harm occurs due to product dispersion
Solution Approach 1:
The envelope creates a controlled, contained environment around the Galle chain during maintenance operations. This enclosed space prevents maintenance products from dispersing into the external environment, effectively isolating the chemical processes within a bounded zone that protects surrounding flora and fauna while maintaining cleaning and lubrication effectiveness
Solution Approach 2:
The system recovers and recycles maintenance products through the envelope containment system rather than allowing them to be discarded into the environment. Excess cleaning and lubricating products are captured within the envelope and can be reused, eliminating environmental contamination while ensuring thorough maintenance application
3Reliability
If the Galle chain is completely cleared for maintenance, then thorough maintenance can be performed, but the lock requires draining and refilling which takes four weeks
Solution Approach 1:
The maintenance system extracts only the specific portion of the Galle chain that requires maintenance into the envelope, rather than requiring complete removal or draining of the entire lock system. This localized approach allows maintenance to be performed on isolated sections while the lock remains operational, reducing downtime from four weeks to a fraction of that time
Solution Approach 2:
The system prepares maintenance conditions in advance by positioning the envelope and equipment before actual maintenance begins, allowing cleaning and lubrication to occur without interrupting lock operations. This preliminary setup enables maintenance to be performed on-the-fly during normal lock operation, eliminating the need for complete system drainage and refilling
4Device complexity
If fixed geometry maintenance equipment is used, then the device structure is simple, but it cannot accommodate different Galle chain geometries
Solution Approach 1:
The envelope and projection members are designed with dynamic adjustment capabilities that allow real-time modification of geometry to match different Galle chain configurations. This dynamic adaptability enables a single device structure to accommodate various chain sizes and shapes without requiring multiple specialized equipment sets, maintaining structural simplicity while achieving versatility
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
Enables safe, efficient, and environmentally friendly maintenance of Galle chains by containing cleaning and lubricating products, reducing operator risk and environmental impact, and accommodating various chain geometries with a single assembly.
Implementation Method 1
an envelope arranged to surround said portion of the elongated element and the or each projection member, so as to retain an excess of maintenance product or residues resulting from maintenance operations
Implementation Method 2
at least one projection member arranged to project a flow of cleaning product towards a portion of the elongated element
Data Source
Figure 1
Figure 2~3
Figure 4~9
AI summary
The assembly (1) has projectors (111, 112) projecting flow of maintenance products in direction of a portion of an elongated element i.e. Galle chain (2), when the assembly is guided along the elongated element by a flange-roller (101). A casing (119) encloses the portion of the elongated element and the projectors so as to retain excess of the products or residues issued from maintenance operations. The casing comprises passage openings (121, 122) for passage of the elongated element. Sealing elements close the openings in a sealed manner. The projectors are connected to reservoirs containing cleaning products such as dry ice crystals and oil, respectively. The sealing elements are formed of brushes (124) and cover flaps (125). An INDEPENDENT CLAIM is also included for a method for performing maintenance operations on an elongated metal element.