I-Beam Hinge Bracket for Bucket Weight Reduction
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Solution Overview
Problem
Existing bucket hinge designs are heavier than desirable, leading to increased stress, machine downtime, fuel inefficiency, and reduced tire life due to excessive weight, which necessitates repair or replacement.
Innovation Solution
A lighter and more durable upper hinge design featuring I-beam configured hinge attachment brackets with pin receiving bores, reducing weight and distributing stress more effectively through a radial and longitudinal axis, thereby enhancing the bucket's structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welded brackets and gussets are added to strengthen the hinge, then the strength and durability of the bucket hinge is improved, but the bucket weight increases significantly
Solution Approach 1:
The hinge attachment bracket is divided into multiple components: a main bracket body, separate gusset plates welded to reinforce specific stress areas, and a pin assembly. This segmentation allows strategic reinforcement only where needed rather than uniformly strengthening the entire structure, reducing unnecessary weight while maintaining hinge strength at critical locations.
Solution Approach 2:
The hinge assembly utilizes composite construction combining different steel grades and thicknesses - heavier gauge steel for the main bracket body and pin, lighter gauge steel for the gusset plates and non-critical areas. This composite approach optimizes the strength-to-weight ratio by applying material strength selectively where structural demands require it.
2Reliability
If heavier hinge design is used to endure repeated stress, then the reliability of the bucket hinge is improved, but the machine fuel efficiency deteriorates
Solution Approach 1:
The design optimizes geometric parameters of the bracket including flange width, web thickness, and gusset plate dimensions to achieve the minimum weight necessary for reliable operation. Finite element analysis was used to determine optimal parameter values that provide adequate strength while minimizing mass, directly improving fuel efficiency.
Solution Approach 2:
Instead of uniformly over-designing the entire hinge assembly, the solution applies reinforcement (gusset plates) only in specific partial areas where stress concentrations occur during cyclic loading. This partial action approach provides sufficient reliability for enduring repeated stress while avoiding the fuel efficiency penalty of excessive overall weight.
3Duration of action of stationary object
If additional welding and gussets are added to strengthen the hinge, then the durability of the bucket is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The bracket is designed as an assembled construction of separate pieces (main bracket, gusset plates, pin) rather than a single monolithic component. This segmentation enables modular manufacturing where components can be fabricated separately using standard shop processes and then assembled with welding, improving manufacturing ease while maintaining durability through proper joint design.
Solution Approach 2:
Gusset plates serve as intermediary elements that simplify the connection between the bracket and adjacent structural members. These intermediate components provide convenient welding surfaces and stress distribution paths, making the overall assembly easier to manufacture and inspect while enhancing the durability of the hinge connection.
Data Source
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AI summary
A hinge attachment bracket for use with a work implement is provided. The bracket comprises a substantial I-beam configuration that includes a first flange, a second flange, a web that connects the first flange to the second flang and that defines a boss that defines a pin receiving bore that establishes a radial direction, a radial plane and a longitudinal axis. The first and second flanges may merge toward each other tangentially forming a first extension portion.