Adjustable Pulley Hanger Assembly for Liquid Level Gauge Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pulley systems for liquid level gauges are difficult to adjust, prone to misalignment, leading to excessive wear on cables and pulley wheels, and are not easily installable or cost-effective for wide applications.
Innovation Solution
A pulley assembly with an elongate hanger supported by a base bracket and pulleys equipped with clamps for easy positioning and secure fixing, ensuring pulley alignment and minimizing wear, using SAE 304 stainless steel for durability and corrosion resistance, and polyamide sheaves for reduced wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pulleys are placed within the interior space of encompassing frame members as in prior art, then the cable guidance means can be provided, but the adjustment becomes difficult and time-consuming
Solution Approach 1:
The pulleys are extracted from the interior space of the encompassing frame members and mounted on the exterior surface of the tank. This allows easy access for adjustment while maintaining the cable guidance function. The pulleys are positioned on the outer surface where they can be readily accessed for positioning and adjustment without disassembling frame structures.
Solution Approach 2:
The pulleys are made adjustable and repositionable on the tank surface rather than being fixed in place. This dynamic positioning capability allows the system to be easily adjusted during installation and maintenance, resolving the contradiction between providing reliable cable guidance and enabling easy adjustment.
2Ease of manufacture
If pulleys are not precisely aligned, then installation is simpler, but excessive wear occurs on cable and pulley wheels
Solution Approach 1:
Alignment features and guide structures are built into the pulley mounting system beforehand, ensuring that pulleys are pre-aligned during manufacturing. This preliminary alignment action prevents excessive wear during operation while maintaining simple installation procedures, as the alignment is already established before field installation.
Solution Approach 2:
The pulley system incorporates self-aligning features where the pulleys automatically maintain proper alignment through their mounting mechanism. This self-service alignment capability ensures consistent cable tracking and minimizes wear without requiring complex adjustment procedures or specialized installation tools.
3Reliability
If a secure mounting system is provided, then the pulley assembly is stable, but the installation becomes more complex
Solution Approach 1:
The mounting system is divided into separate modular components including base brackets, mounting plates, and adjustable pulley assemblies. Each segment can be independently installed and positioned, providing secure mounting while simplifying the overall installation process. The modular segments can be assembled in straightforward sequences without complex integration steps.
Data Source
AI summary
A pulley assembly includes an elongate pulley hanger, supported at the upper end of a pillar rising from and dependently supported by a base bracket, and first and second pulleys slidingly supported by the pulley hanger. The base bracket securely mounts the pulley assembly to the top of a liquid storage tank. Each provided pulley implements, or is otherwise provided with, a clamp, whereby each pulley is readily positioned along the pulley hanger, and, when in a desired position, easily and securely fixed in the desired position.