Longwall Shearer Gear Axle Cooling via Internal Channels

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Solution Overview

Problem

Conventional longwall shearer ranging arm gear cases face challenges in efficiently removing heat without increasing size or incurring high costs, as traditional cooling methods often lead to contamination and require larger packages.

Innovation Solution

The proposal involves drilling coolant channels into the gear mounting axles, allowing water to be transmitted through these axles to remove heat near the source, utilizing existing space without increasing the gear case's volume or complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a separate water-cooled heat exchanger is mounted in the oil reservoir, then heat removal capability is improved, but the gear case size increases and contamination risk increases

Engineering Contradiction:

Improveheat removal capabilityVSAvoidgear case size

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The coolant channels are drilled directly into the existing gear mounting axles, nesting the cooling function within the structural components already present in the gear case. This eliminates the need for separate heat exchanger units and avoids increasing the overall gear case volume.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The cooling function is merged with the gear mounting axles by drilling channels through them. The axles serve dual purposes: supporting the gears structurally and removing heat through internal coolant flow, thereby combining structural and thermal management functions into a single component.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If a heat exchanger is built into the housing, then heat removal capability is improved, but manufacturing cost increases and contamination risk increases

Engineering Contradiction:

Improveheat removal capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The cooling channels are integrated directly into the gear mounting axles during the axle manufacturing process. This merging of cooling functionality with existing structural components eliminates the need for separate heat exchanger manufacturing, assembly, and sealing operations, thereby reducing manufacturing complexity and cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cooling function is extracted from the housing structure and relocated to the gear mounting axles. This extraction simplifies the housing design and eliminates the need for complex integrated heat exchanger assemblies, reducing manufacturing steps and costs.

Inventive Principle:

Principle #2Taking out (Extraction)

3Temperature

If conventional cooling methods are used, then heat removal is achieved, but water ingress into lubricating oil becomes a risk

Engineering Contradiction:

Improveheat removalVSAvoidcontamination prevention

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The coolant flow path is merged with the gear mounting axles, which are solid metal components. This integration eliminates the need for separate water seals and connections between independent cooling and lubrication systems, thereby eliminating the primary pathways for water ingress into the lubricating oil.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The gear mounting axles serve as an intermediary structure that conducts heat from the gears while being impermeable to water. The solid metal axles act as a barrier that prevents water from the cooling system from mixing with the lubricating oil in the gear case.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method effectively removes heat from the gear case without enlarging the package, is cost-effective, prevents water ingress, and maintains the gear case's compact design, ensuring reliable operation and longevity.

Implementation Method 1

drilling coolant channels into the gear mounting axles, allowing water to be transmitted through these axles to remove heat near the source

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

coolant leaving the end of the coolant injection tube travels back along the coolant injection tube and then out of the gear axle thereby removing heat from the single gear

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS8439451B2Cooling a ranging arm gear case on a longwall shearer

Publication Date: 2013.05.14 JOY GLOBAL UNDERGROUND MINING LLC

AI summary

A cooling system for the gear case in the ranging arm of a longwall shearer, the ranging arm including a plurality of single gears mounted in a row within an elongated housing. The cooling system includes a coolant injection system in each of the single gears, each coolant injection system including a longitudinal opening in the gear axle, and a coolant injection tube mounted inside the longitudinal opening. The coolant injection tube has a diameter smaller than the diameter of the longitudinal opening. A coolant supply line is connected to and in communication with the coolant injection tube, and a coolant outlet is connected to and in communication with the longitudinal opening adjacent the one end of the longitudinal opening, so that coolant leaving the end of the coolant injection tube travels back along the coolant injection tube and then out of the gear axle thereby removing heat from the single gear.