Non-Metallic Conveyor Chain Structure for Sludge Collector Durability
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Solution Overview
Problem
Conventional metallic conveyor chains used in sludge collectors for sedimentation basins suffer from frequent fractures and sagging due to high tensile forces, leading to maintenance and operational inefficiencies, especially in large sedimentation basins.
Innovation Solution
A non-metallic conveyor chain with improved durability is achieved by enhancing the chain link structure, distributing shear load between the chain pin, barrel, and yoke through features like grooved chain pockets and chain bosses, and using high-strength steel-reinforced plastic (SRP) chain pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic conveyor chains are used in sludge collectors, then the chains can withstand high tensile forces, but they suffer from frequent fractures and sagging due to high tensile forces
Solution Approach 1:
The patent applies composite materials by combining a non-metallic base material (such as polyacetal or polyethylene) with steel reinforcement elements (steel wires or steel rods embedded within the chain structure). This composite construction provides both the flexibility and corrosion resistance of non-metallic materials and the high tensile strength of steel, thereby resolving the contradiction between strength and durability. The steel reinforcement is integrated into the chain links to withstand high tensile forces while the non-metallic exterior prevents corrosion and reduces weight.
2Device complexity
If conventional chain link structures are used, then the structure is simple, but shear load is concentrated on the chain pin leading to frequent fractures
Solution Approach 1:
The patent applies segmentation by dividing the chain link into distinct functional components: a base link body, a chain pin, a chain boss protruding from one link, and a chain pocket recessed in the adjacent link. This segmentation allows each component to bear specific loads - the chain boss and pocket distribute shear forces away from the chain pin, while maintaining a relatively simple overall structure. The segmented design enables the chain pin to focus on tensile loading while the boss-pocket interface handles shear loading.
Solution Approach 2:
The patent applies local quality by creating localized structural features - the chain boss protrusion and chain pocket recess - at specific locations where shear forces occur. These localized modifications concentrate material and structural support precisely where needed to counteract shear forces, while leaving the rest of the chain structure simple and lightweight. The boss and pocket create a localized load-bearing interface that protects the chain pin without requiring complex overall redesign.
3Weight of moving object
If non-metallic materials are used for conveyor chains, then weight is reduced and corrosion resistance is improved, but durability under high tensile forces is insufficient
Solution Approach 1:
The patent applies composite materials by combining a non-metallic base material (such as polyacetal or polyethylene) with steel reinforcement elements (steel wires or steel rods embedded within the chain structure). This composite construction provides both the flexibility and corrosion resistance of non-metallic materials and the high tensile strength of steel, thereby resolving the contradiction between strength and durability. The steel reinforcement is integrated into the chain links to withstand high tensile forces while the non-metallic exterior prevents corrosion and reduces weight.
Data Source
AI summary
A non-metallic conveyor chain having improved durability as a conveyor chain for a sludge collector, the conveyor chain including a plurality of unit chains and chain pins with which the unit chains are linked to each other, wherein each of the unit chains is provided at one side thereof with a barrel and at the other side thereof with a yoke. The barrel of the unit chain is formed on an outer surface thereof with a chain pocket having a groove structure, and the yoke of the unit chain is formed on an inner surface thereof with a chain boss protruding so as to correspond to the chain pocket of the unit chain to which the chain boss is to be linked.