Sliding Gate Rack Design with 180-Degree Connector
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Solution Overview
Problem
Current methods for producing gate racks are costly and inefficient, requiring thick metal sheets and extensive processing, including hot rolling, slotting, and galvanizing, which complicates the production of high-quality teeth and increases costs.
Innovation Solution
A rack design featuring two parallel flat portions connected by a 180-degree curved connector, made from cold-rolled steel strips, with teeth formed by shearing and bending, allowing for efficient production using common metal processing machines and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick metal sheets (greater than 8 mm) are used for the rack, then the rack can safely resist mechanical stresses from pinion engagement, but the production cost increases and material usage is excessive
Solution Approach 1:
The rack is divided into two separate flat portions (first and second flat portions) that are connected by a curved connector portion. Each flat portion can be processed independently with thinner gauge metal, reducing overall material usage while maintaining structural integrity when assembled together.
Solution Approach 2:
The rack is constructed as a composite structure combining multiple metal components (flat portions and connector) that work together to achieve the required strength. This allows optimization of each component's thickness and material properties rather than using uniformly thick metal throughout.
2Reliability
If traditional hot rolling and slotting processes are used to create teeth on thick metal bars, then the teeth can engage the pinion reliably, but the production cost and processing time increase significantly
Solution Approach 1:
The teeth are formed on the flat portions before the bending and assembly operations. By pre-forming the teeth on thinner, more manageable metal sheets, the subsequent bending and welding operations can proceed faster without compromising tooth integrity, thereby increasing overall production speed.
Solution Approach 2:
The invention changes the physical state and dimensions of the metal from thick bars requiring hot rolling to thinner sheets suitable for cold forming and faster processing. This parameter change enables the use of more efficient, lower-cost manufacturing processes while maintaining tooth engagement reliability.
3Reliability
If extensive surface operations (washing, pickling, galvanizing) are performed on hot-rolled metal bars, then the surface quality and corrosion resistance improve, but the production cost and processing complexity increase
Solution Approach 1:
The invention changes the processing parameters from high-temperature hot rolling requiring extensive surface treatment to cold-rolled or cold-formed thinner metal sheets. These thinner sheets require fewer and less complex surface operations while achieving adequate corrosion resistance and surface quality for the application.
4Productivity
If shearing operations via press or punching machine are used to create teeth, then the production speed increases, but the teeth quality and tolerance are insufficient for reliable pinion engagement
Solution Approach 1:
The teeth are formed on the flat portions before the final bending and assembly operations. This preliminary tooth formation allows for better control of tooth geometry and tolerance on the flatter, more stable metal sheets, while the subsequent bending operations do not compromise the already-formed teeth.
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 solution provides a cost-effective, reliable, and aesthetically pleasing rack that is easy to install and resistant to mechanical stresses, while minimizing material usage and processing costs.
Implementation Method 1
A rack design featuring two parallel flat portions connected by a 180-degree curved connector, made from cold-rolled steel strips
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Rack, preferably intended to be mounted on a slidable gate, formed by an elongated body made of steel having two flat portions (10) that are facing and parallel to each other, joined at one end by a connector portion (12) that has 180-degree shape with at least one bend and provided at the other end with toothings (14), with the teeth (15) transversely aligned in order to allow the toothing of a pinion to engage both toothings (14) simultaneously.