Modular Wear Surface for Mining Equipment
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Solution Overview
Problem
Equipment operating in abrasive environments, such as mining equipment, experiences excessive wear and erosion, leading to frequent maintenance and extended downtime due to the labor-intensive process of applying and replacing hardfacing wear layers, which are difficult to weld and require custom-made liners and specialized tools.
Innovation Solution
A wear surface composed of alternating hard wear members and retention members that can be easily trimmed and attached to equipment surfaces without specialized tools, using a flexible backing to maintain spacing and sequencing, allowing for easy installation and replacement, and reducing the need for custom fasteners and extensive equipment downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardfacing is applied to extend service life, then wear resistance is improved, but equipment downtime increases due to labor-intensive application
Solution Approach 1:
The wear surface is divided into multiple replaceable wear members (e.g., blocks or tiles) that can be independently installed and removed. This segmentation allows for quick replacement of worn components without requiring extensive hardfacing operations, thereby reducing equipment downtime while maintaining wear resistance through modular replacement.
2Reliability
If custom-made liners are used to cover larger areas, then wear protection is improved, but device complexity increases due to specialized attachment systems
Solution Approach 1:
The wear members are designed with standardized features that allow them to be used across different equipment surfaces and configurations. The retention members can accommodate various wear member shapes and sizes, creating a universal attachment system that reduces complexity compared to custom-made liners requiring specialized attachment systems for each application.
3Reliability
If multiple wear members are used to cover large surfaces, then wear resistance is improved, but ease of manufacture decreases due to extensive installation requirements
Solution Approach 1:
The wear members are pre-assembled with retention members or pre-configured with attachment features during manufacturing. This preliminary preparation allows for rapid field installation without requiring complex assembly procedures, improving ease of manufacture while maintaining the wear resistance benefits of multiple wear members covering large surfaces.
Data Source
AI summary
A wear surface that is easily modified and fitted for installation to a wearable surface includes alternating longitudinal wear members and retaining members. The wear members consist of a hard material such as white iron with good wear resistance. The retaining members are of a ductile material that is readily welded and overlap the wear members on each side over at least a portion of their length. The retaining members can be welded to the equipment to be protected and retain the wear members which are not readily welded.