Modular Water Spray Assembly for Pick Box Maintenance
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Solution Overview
Problem
Existing water spray nozzles in pick boxes of mineral winning machines are prone to damage and blockage, leading to costly replacements and potential machine shut-downs, as they require frequent inspection and replacement to maintain optimal operation.
Innovation Solution
A two-component water spray assembly consisting of a spray body and a co-axial spray nozzle, where the nozzle can be removed and replaced independently from the rear without disturbing the spray body, allowing for unit removal or nozzle-only replacement, with features like hexagonal sockets and resilient sealing rings for easy maintenance and reduced wear on the spray body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single integrated spray nozzle is used in the pick box, then the spray assembly is simple in structure, but the nozzle requires frequent replacement due to damage and blockage, increasing maintenance costs and time
Solution Approach 1:
The spray assembly is divided into two separate components: a spray body and a spray nozzle, which are connected via screw threads. This segmentation allows the nozzle to be removed and replaced independently from the spray body, enabling maintenance without replacing the entire assembly. The spray body remains in the pick box while only the worn nozzle is replaced, reducing maintenance time and costs.
2Reliability
If the entire spray assembly is replaced when the nozzle is damaged, then the spray body is protected from wear, but maintenance costs and time increase due to replacement of the expensive precision nozzle
Solution Approach 1:
By separating the spray body and nozzle into independent components with threaded connection, the system enables selective replacement of only the worn nozzle while retaining the durable spray body in the pick box. This eliminates the need to replace the entire assembly, reducing maintenance time and preserving the investment in the spray body.
Solution Approach 2:
The design allows the spray body to be recovered and retained in the pick box after nozzle replacement, while only the worn nozzle is discarded and replaced. This maximizes the useful life of the expensive precision components by protecting the spray body from wear and damage during maintenance operations.
3Ease of manufacture
If the spray nozzle is screwed into the receiving bore from the front, then installation is simple, but the nozzle is prone to damage and blockage during operation
Solution Approach 1:
The spray nozzle is designed to be screwed into the receiving bore from the rear end rather than the front. This inverted installation approach protects the nozzle from direct exposure to damaging conditions during operation, reducing blockage and damage while maintaining ease of installation through the threaded connection system.
4Area of stationary object
If multiple spray nozzles are installed in the pick box, then water distribution coverage is improved, but the probability of blockage and damage increases, requiring frequent monitoring and maintenance
Solution Approach 1:
The modular design of separate spray bodies and nozzles with threaded connections enables independent maintenance of each nozzle. When multiple nozzles are installed in the pick box, any blocked or damaged nozzle can be quickly removed and replaced without affecting the others, reducing overall maintenance frequency and improving operational reliability.
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 design minimizes maintenance costs by allowing only the nozzle to be replaced when worn or damaged, extending the life of the spray body and preventing automatic machine shut-downs, while maintaining efficient water distribution and spray pattern.
Implementation Method 1
The spray body is provided with two resilient water sealing rings, one located each side of the circumferential groove, in a sealing ring receiving groove
Implementation Method 2
the two components being releasably connected together by means of screw threads
Implementation Method 3
a water supply bore of the pick box, which bore is adapted to convey pressurized water from a supply source
Implementation Method 4
The spray body is provided with an internal, water-receiving chamber to which water is conveyed by at least one inlet bore, from the circumferential groove
Data Source
AI summary
A water spray assembly for replaceable location in a receiving bore of a pick box, which pick box is also adapted to receive a replaceable mineral cutter pick, is constructed from two components. One component is a spray body and the other component is a co-axial spray nozzle. The two components are releasably connected together by screw threads, whereby the spray assembly may either be removed from or inserted into, its receiving bore as a whole, or alternatively as individual components.