Mast Rack Assembly Segmentation for Mining Drill Rigs
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Solution Overview
Problem
Current rack structures in blasthole drill rigs are cumbersome to assemble and maintain, leading to increased time and costs, and may not provide adequate strength and durability for drilling through hard rock in mining applications.
Innovation Solution
A mast and rack assembly design featuring outer and inner rails, rack segments, and a pinion-driven mechanism with staggered and overlapping configurations to enhance strength, assembly efficiency, and maintenance accessibility, utilizing removable components for reduced costs and extended fastener life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rack segments are welded in place onto the mast, then the rack structure provides adequate strength and durability, but the assembly and maintenance become cumbersome and time-consuming
Solution Approach 1:
The rack is divided into multiple rack segments that can be independently installed and removed. Each segment is positioned between the outer rails and can be attached using removable fasteners rather than permanent welding, allowing for efficient assembly and maintenance while maintaining structural integrity through the overlapping configuration with outer rails
Solution Approach 2:
The rack segments are designed with dynamic attachment capabilities through removable fasteners, transitioning from a static welded structure to a dynamic assembly that can be easily configured, adjusted, and maintained. This allows the rack to maintain strength during operation while enabling quick disassembly when needed
2Duration of action of stationary object
If rack segments are placed in abutting relationship and welded in place, then the structure is durable, but maintenance accessibility and component replacement become difficult
Solution Approach 1:
The rack is segmented into multiple independent sections that can be accessed and replaced individually. The removable fastener system allows maintenance personnel to access and replace specific rack segments without disturbing the entire structure, significantly improving maintenance accessibility while maintaining overall durability
Solution Approach 2:
The rack segments are extracted from the permanent welded structure and made removable through the fastener system. This extraction allows individual segments to be taken out for maintenance or replacement while the rest of the rack remains in place, improving ease of repair without compromising the durability of the remaining structure
3Ease of manufacture
If traditional rack structures are used, then assembly is straightforward, but assembly time and costs increase
Solution Approach 1:
The rack is divided into pre-fabricated segments that can be manufactured independently and then quickly assembled on-site using the removable fastener system. This segmentation simplifies the manufacturing process for each component while dramatically reducing total assembly time compared to traditional welded rack structures
Solution Approach 2:
The rack segments and fastener components are pre-configured and pre-positioned in the design, allowing for rapid assembly without complex field welding operations. The overlapping configuration with outer rails is built into the segment design, enabling quick installation while maintaining structural integrity
Data Source
AI summary
A mast and rack assembly for a mining machine includes a mast and a rack assembly coupled to the mast. The rack assembly includes outer rails and rack segments disposed between the outer rails and the mast. At least one of the outer rails overlaps two of the rack segments.