Pluggable Dumper Floor Profile Without Weld Cracking
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Solution Overview
Problem
Current dumper vessel floor designs are prone to deformations and cracking due to welding, leading to weight adherence issues, increased risk of tipping, and high maintenance costs, as well as excessive weight and fuel consumption.
Innovation Solution
A dumper floor profile with interlocking lower and upper profiles that eliminate the need for welding, using an elastic wedge for impact absorption and intermediate cross reinforcement to prevent deflection, allowing for easy installation and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join floor sheet and supporting crosses, then strength is improved, but deformations and cracks occur
Solution Approach 1:
The floor structure is divided into separate modular components: floor sheets and supporting crosses are distinct elements that can be independently replaced. The supporting crosses are segmented into multiple pieces that can be individually swapped without affecting the entire floor structure.
Solution Approach 2:
The floor sheets and supporting crosses are extracted from the welded assembly and converted into removable, interchangeable components. Damaged floor sheets can be taken out and replaced without removing the supporting crosses, and vice versa.
2Strength
If welding is used to join floor sheet and supporting crosses, then strength is improved, but repair costs and weight increase
Solution Approach 1:
The floor sheets and supporting crosses are designed as inexpensive, easily replaceable components. Instead of performing costly welding repairs, damaged parts can be quickly swapped out for new ones, reducing both repair costs and the weight added by repair patches.
3Ease of manufacture
If floor sheet distance from supporting cross is excessive, then ease of manufacture is improved, but permanent deflections and deformations occur
Solution Approach 1:
The supporting crosses are designed with flexibility to adapt to varying distances from the floor sheet. The crosses can flex and deform elastically to accommodate different sheet positions without causing permanent deflections, while still providing adequate support.
4Strength
If welding is used to join floor sheet and supporting crosses, then strength is improved, but labor cost and installation time increase
Solution Approach 1:
The floor assembly is segmented into pre-fabricated floor sheets and supporting crosses that can be quickly assembled together using simple connection methods, eliminating the time-consuming welding process while maintaining structural strength.
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 solution provides a strong, lightweight, and easily repairable dumper floor profile that prevents deformation and weight adherence, reducing the risk of tipping and maintenance costs while improving load discharge efficiency.
Implementation Method 1
at least one impact dampener elastic wedge (4) arranged between the dumper vessel (1) and the dumper chassis (15)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention is the floor profile (3) of the aluminum box type dumpers used for the transportation of the construction materials, having a pluggable construction, wherein the invention relates to a floor profile body (11), which houses the other components on, at the side, or beneath itself, and bears the impact, abrasion and force effect by bearing the load on itself, contacting elements in different forms created on the floor profile body (11), the intermediate cross (12) located underneath the floor profile body (11), which supports the floor profile body (11) with regard to reinforcement and resistance, the intermediate cross reinforcement (16), which ensures that the main cross (12) is reinforced, the wedge homing protrusion (14), which makes sure that impact dampener element is attached to the floor profile body (11) with the interlocking method, and the wedge surface (13) located on the bottom surface of the wedge homing protrusion (14), which secures the impact dampener element.