Quick Coupler Wedge Angle Optimization for Mining Implements
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Solution Overview
Problem
Existing quick couplers for mining and construction machinery, such as the '571 coupler, face issues with inadequate wedging action, sticking problems, and high manufacturing costs, making them inefficient and costly for use in attaching and detaching implements.
Innovation Solution
A quick coupler design featuring a tube with hydraulic cylinders that extend and retract wedges into wedge pockets on the implement, with wedge coupling surfaces forming an angle of 60 to 44 degrees for optimal wedging action, minimizing movement and wear, and allowing easy attachment and detachment of implements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the wedge coupling surfaces form a smaller angle, then the wedging action is stronger and the tight fit is maintained, but the sticking problem increases making removal difficult
Solution Approach 1:
The patent specifies that the wedge coupling surfaces form an angle between 45 and 60 degrees, which is an optimized parameter range that balances strong wedging action with ease of removal. This parameter optimization resolves the contradiction by finding the optimal angle that provides sufficient holding strength while preventing excessive sticking that would make removal difficult.
2Ease of manufacture
If a pin-style joint is used, then the manufacturing cost is low, but the implement switching is time-consuming and requires considerable skill
Solution Approach 1:
The patent employs hydraulic cylinders to actuate the wedges for automatic implement attachment and detachment. The hydraulic system allows the operator to control implement switching from inside the cab, dramatically increasing switching speed and eliminating the need for manual pin handling while maintaining cost-effectiveness through the use of standard hydraulic components.
Solution Approach 2:
The quick coupler system enables the implement switching operation to be performed automatically by the machine's own hydraulic system under operator control, eliminating the need for external technicians or manual intervention. The system serves itself by using the machine's existing hydraulic power to perform the coupling and uncoupling actions.
3Reliability
If the coupler design is more complex to achieve better wedging action, then the coupling reliability improves, but the manufacturing cost increases
Solution Approach 1:
The quick coupler is divided into modular components including the body, separate wedge elements, hydraulic cylinders, and coupling surfaces. This segmentation allows each component to be manufactured independently using standard processes and then assembled, achieving reliable coupling performance while controlling manufacturing costs through modularity and standardization.
Solution Approach 2:
The patent optimizes the angle of the wedge coupling surfaces to be between 45 and 60 degrees, which provides reliable wedging action through geometric optimization rather than through complex mechanisms. This parameter-based solution achieves high coupling reliability while keeping the design simple and cost-effective to manufacture.
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 secure, efficient, and cost-effective means of attaching and detaching implements, maintaining a tight fit despite wear, and minimizing kinematic interference with the machine, while allowing clear visibility and precise positioning.
Implementation Method 1
a tube adapted to be received in hooks on a second body, at least two wedges arranged for retraction and extension movement, and adapted to be extended into and retracted from wedge pockets formed on the second body
Data Source
AI summary
A quick coupler includes mounting structure for mounting the coupler to a machine, and for mounting the coupler to an implement. The mounting structure on the coupler includes wedge coupling surfaces and a tube. The mounting structure on the implement includes hooks for engaging the tube, and complementary wedge coupling surfaces. The wedge coupling surfaces wedge together during coupling to produce and tight fit and solid hold between the coupler and implement. The mounting structure is robust, and can accommodate future possible wear. The kinematic impact on the performance of the implement due to the use of the quick coupler is minimized.