Polymer Tail Roller Assembly for Noise Reduction
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Solution Overview
Problem
Continuous miners generate high noise levels due to steel-on-steel impacts and vibrations in the pivoting boom area, particularly at the tail roller and take-up mechanism, which are not effectively mitigated by existing technologies.
Innovation Solution
The introduction of a polymer-based tail roller assembly with a pliable elastomer and polymer flex-boards to absorb energy, reduce noise, and eliminate steel-on-steel impacts, combined with a take-up system that maintains chain tension while minimizing vibrations and noise-producing movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel conveyor chains and steel components are used in the tail roller assembly, then structural strength and durability are improved, but noise levels increase due to steel-on-steel impacts and vibrations
Solution Approach 1:
The patent applies composite materials by combining steel structural components with polymer elements. The tail roller assembly uses steel for structural strength while incorporating polymer flex-boards, polymer cushions, and pliable elastomers to absorb impacts and reduce noise. This composite approach maintains the necessary structural integrity while eliminating steel-on-steel impacts that generate excessive noise.
Solution Approach 2:
The patent introduces polymer intermediaries between steel components to reduce direct metal-to-metal contact. Polymer flex-boards are positioned between steel structures, and pliable elastomers are placed between the conveyor chain and steel components. These intermediary polymer elements absorb impact energy and dampen vibrations, preventing noise-generating steel-on-steel impacts while maintaining functional connectivity.
2Reliability
If conventional take-up mechanisms with multiple adjustment points are used, then chain tension can be maintained, but noise-producing vibrations and rattle points increase
Solution Approach 1:
The patent extracts and eliminates noise-producing elements from the take-up mechanism. By removing traditional multiple adjustment points and associated linkages that create rattle points and vibrations, the design simplifies the mechanism to a single adjustment point. This extraction of unnecessary components maintains chain tension functionality while eliminating the sources of noise and vibration.
Solution Approach 2:
The patent changes the operational parameters of the take-up mechanism by reducing the number of adjustment points from multiple to a single adjustment point. This parameter change simplifies the mechanism, reduces the number of moving parts that can generate noise, and maintains effective chain tension control with fewer vibration-generating movements.
3Adaptability or versatility
If multiple adjustment points are provided in the take-up mechanism, then chain tension can be adjusted, but device complexity and number of parts increase
Solution Approach 1:
The patent extracts unnecessary adjustment points from the take-up mechanism, reducing the system from multiple adjustment points to a single adjustment point. This extraction eliminates redundant components and simplifies the overall device structure while maintaining the essential functionality of chain tension adjustment.
Solution Approach 2:
The single adjustment point in the patent is designed to perform multiple functions: it adjusts chain tension, compensates for chain wear, and maintains proper chain alignment. This multi-functional design eliminates the need for separate adjustment mechanisms, reducing device complexity while preserving adaptability.
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
Significantly reduces noise levels by dampening vibrations and eliminating rattle points, providing effective noise shielding and maintaining chain tension without the need for adjustments, thus improving operational conditions in underground mining environments.
Implementation Method 1
a pliable elastomer sandwiched between the discharge boom side frame and each of the slide plate guides
Implementation Method 2
absorb energies that would otherwise produce high decibels
Implementation Method 3
a polymer-based cushion connected between the end of the cylinder and the discharge boom side frame
Implementation Method 4
polmer flex-boards to absorb energy, reduce noise, and eliminate steel-on-steel impacts
Data Source
AI summary
A mining machine comprising a discharge boom including a tail slide plate slidably connected between left and rear side frames, and a tail roller assembly mounted on the tail slide plate. The tail roller assembly includes a take-up roller mounted centrally between the side frames and between a pair of spacer blocks and a pair of bearing blocks, each of the spacer blocks and bearing blocks being connected to a rearward edge of the tail slide plate. The mining machine also has an opening in each of the side frames, and two slide plate guides, one on each side frame, each of which is positioned outside of the respective side frame adjacent a respective one of the side frame openings, and mounted for sliding movement relative to its respective side frame. The tail slide plate has opposed outside edges received within a respective one of the slide plate guides, and a pair of take up cylinders, one on each side frame, each of which is connected to and extending between the respective side frame and the end of the slide plate guide. The tail roller assembly also includes a pliable elastomer and/or wear material sandwiched between the inside of each of the tail slide plate guides and the outside of each of the side plates, and a polymer-based cushion is connected between the end of the cylinder and the boom side frame.