Pallet Car Exchange Mechanism for Continuous Sintering Plants
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Solution Overview
Problem
In pelletizing or sintering plants, conventional pallet car exchange requires shutting down the lifting wheel for 5 to 10 minutes, causing additional thermal damage and disrupting production, and existing continuous exchange methods require additional lifting and conveying mechanisms, which are complex and costly.
Innovation Solution
A switch-based system that allows pallet cars to be removed and inserted without shutting down the plant, using a fixed switch and pivotable curve links to open the rail guides, eliminating the need for additional gripping and conveying mechanisms, and incorporating a pulling device for removal and a pushing device for insertion, with a secondary arc for manual operation in case of damaged pressure rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pallet car exchange is performed by shutting down the lifting wheel, then the exchange operation can be completed, but production is stopped and thermal damage to pallet cars increases
Solution Approach 1:
The patent applies dynamics by making the rail guides movable rather than fixed. The first and second rail guides can be moved between a closed position (guiding pallet cars normally) and an opened position (allowing pallet car exchange). This dynamic capability enables continuous operation during pallet car exchange, eliminating production stoppages while maintaining exchange reliability
Solution Approach 2:
The patent segments the rail guide system into multiple movable rail guides (first and second rail guides) that can be independently controlled. This segmentation allows one section to remain closed and guiding while another is opened for exchange operations, enabling continuous production flow during maintenance
2Productivity
If additional lifting and conveying mechanisms are added for continuous pallet car exchange, then production continuity is maintained, but device complexity and cost increase
Solution Approach 1:
The patent applies self-service by utilizing the pallet cars' own wheels and movement capability to perform the exchange operation. The movable rail guides allow pallet cars to be removed and inserted using their own rolling motion, eliminating the need for separate lifting and conveying mechanisms that would add complexity to the system
Solution Approach 2:
The movable rail guides serve multiple functions: they guide pallet cars during normal operation when closed, and they enable exchange operations when opened. This multi-functionality eliminates the need for dedicated exchange mechanisms, reducing overall device complexity while maintaining continuous production capability
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
Plant for the treatment of bulk materials, such as iron or zinc ore pellets or sinter material, wherein the pallet car (3) are continuously conveyed by means of a lifting wheel (10) and a lowering wheel on rails (8, 9) in an endless chain, an outer curve link (16) of the rail (9) can be opened in the region of a bottom strand of the lifting wheel (10), in order to remove the pallet car (3) from the chain. In the region of the top strand of the lifting wheel (10) an outer curve link (20) of the rail (9) can be opened, in order to insert a new pallet car (3) into the chain. In the region of the bottom strand of the lifting wheel (10) a removal switch (30) is provided, via which a pallet car (3) can be moved out from the chain, while in the region of the top strand of the lifting wheel (10) a supply switch is provided, via which a pallet car (3) can be moved into the chain.