Mining Hammer Drop Weight Rebound Cage Design

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Solution Overview

Problem

Existing mining methods that rely on explosives for primary breakage in rock ore quarries face opposition due to noise, dust, and vibrations, and current mechanical tools like drop hammers and eccentric rippers are not well-suited for repetitive primary breakage and suffer from metal fatigue.

Innovation Solution

A mining hammer apparatus comprising a drop hammer with a moveable drop weight, a shock absorber assembly, and a rebound cage, which allows for controlled impact on rock surfaces without the need for explosives, thereby reducing noise, dust, and vibrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If explosives are used for primary breakage, then rock ore can be broken efficiently, but noise, dust, and vibrations increase causing public opposition

Engineering Contradiction:

Improverock breakage efficiencyVSAvoidnoise, dust, and vibrations

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the chemical energy-based explosive system with a mechanical energy-based drop hammer system. The drop weight delivers controlled mechanical impacts to break rock, eliminating the harmful chemical reactions that produce noise, dust, and vibrations associated with explosives.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The rebound cage acts as an intermediary structure that captures the drop weight after impact and guides it back to the starting position. This intermediary mechanism enables continuous operation without requiring the drop weight to be manually repositioned, maintaining productivity while using non-explosive mechanical breakage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If drop hammers are used for primary breakage, then explosives can be avoided, but the equipment suffers from metal fatigue under repetitive duty-cycle demands

Engineering Contradiction:

Improveelimination of explosivesVSAvoidmetal fatigue resistance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The shock absorber assembly is positioned to cushion the impact of the drop weight before it reaches the rebound cage. This beforehand cushioning reduces the peak forces transmitted to the rebound cage and supporting structure, thereby reducing metal fatigue under repetitive operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent changes the operational parameters by using a very heavy drop weight (6000-7000 pounds) that delivers sufficient breakage force in fewer, more efficient impacts. This parameter change reduces the total number of cycles required compared to lighter hammers, thereby reducing cumulative metal fatigue.

Inventive Principle:

Principle #35Parameter changes

3Power

If a heavy drop weight is used to break rock effectively, then breakage power increases, but the structural components must withstand greater forces

Engineering Contradiction:

Improveimpact breakage powerVSAvoidstructural component strength

Core Design Contradiction:

PowerVSStrength

Solution Approach 1:

The shock absorber assembly provides beforehand cushioning that reduces the peak impact forces transmitted to the rebound cage and supporting structure. This allows the use of a heavy drop weight for effective breakage while protecting structural components from excessive forces.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The rebound cage is designed as a replaceable component that can be worn or damaged and then replaced rather than requiring replacement of the entire drop hammer assembly. This allows the heavy drop weight to be used with protected, replaceable components that absorb the stress.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 mining hammer effectively breaks rock ore from bedrock, reducing the need for explosives and minimizing environmental impact, while also extending the lifespan of mechanical tools by reducing metal fatigue.

Implementation Method 1

a shock absorber assembly coupled to the lower end of the drop hammer

Methodology Applied

Scientific EffectShock absorption: Damping

Implementation Method 2

a rebound cage coupled to the shock absorber assembly and having a series of guides positioned therein

Methodology Applied

Scientific EffectGravitational force: Gravitation

Data Source

PatentUS12286883B1Impact controller for primary rock breakage

Publication Date: 2025.04.29 DALRYMPLE ROBERT H

AI summary

A mining apparatus for primary breakage having a drop hammer with a drop weight that may fall from a first position where the drop weight is suspended within an upper end of the drop hammer and a second position where the drop weight extends from a lower end of the drop hammer. The mining apparatus has a shock absorber assembly coupled to the lower end of the drop hammer with a first passageway through which the drop weight may pass. The mining apparatus also has a rebound cage coupled to the shock absorber assembly and having a series of guides positioned therein and arranged about a second passageway that is in alignment with the first passageway. The rebound cage controls the drop weight when it falls into the second position, strikes the ground, and rebounds.