Composite Track Link With Replaceable Brazed Rail
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Solution Overview
Problem
Track-type machines face severe wear and corrosion issues due to abrasive materials and harsh environments, with existing solutions like hardfacing being cost-prohibitive for widespread use, and current replaceable rails being difficult to remove and replace when worn.
Innovation Solution
A composite track link design featuring a replaceable rail bonded to the link body via brazing or soldering, allowing for easy removal and replacement by heating to a temperature above the filler metal's melting point but below the base metals', enabling extended wear life and cost-effective maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hardfacing materials and processes are applied to the surface of the rail, then wear resistance is improved, but manufacturing cost increases significantly
Solution Approach 1:
The rail is divided into a replaceable portion that can be separated from the link body. This allows the wear-resistant function to be concentrated in the replaceable rail segment, which can be economically manufactured with hardfacing or other wear-resistant treatments, while the link body remains separate and reusable.
Solution Approach 2:
The rail is designed as a replaceable component with a finite service life. When worn, the entire rail can be replaced rather than requiring expensive hardfacing repairs. This disposable approach to the rail component is more economical than applying hardfacing to extend its life, as the replacement cost is lower than the hardfacing process cost.
2Strength
If conventional welding is used to attach the rail to the link body, then joint strength is improved, but ease of replacement deteriorates due to difficulty of removal
Solution Approach 1:
The joining method uses brazing or soldering instead of conventional welding. This changes the thermal and metallurgical parameters of the joint: brazing/soldering creates a strong metallurgical bond sufficient for service loads, but the lower melting point and different joint characteristics allow for easier removal and replacement of the rail when worn.
Solution Approach 2:
A brazing or soldering material acts as an intermediary between the rail and link body. This intermediate layer creates a strong joint during service but allows for controlled removal when replacement is needed, balancing joint strength with replaceability.
3Force
If the track is adjusted tight to reduce friction, then traction is improved, but wear rate increases due to increased contact pressure
Solution Approach 1:
The track tension can be dynamically adjusted based on operating conditions. The replaceable rail design allows the system to accommodate varying tension levels without permanent deformation or excessive wear, as the rail can be replaced when wear occurs from tight adjustment during high-traction operations.
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 extends the working life of track links by allowing for multiple rail replacements without replacing the entire link, reducing costs and maintaining the link body's structural integrity, while providing a strong and durable joint that is as strong as or stronger than the base materials.
Implementation Method 1
heating the body, worn rail and brazing or soldering material to a temperature above the melting temperature of the brazing or soldering material but less than the melting temperatures of the body and worn rail
Implementation Method 2
The replaceable rail includes a brazing or soldering surface that is detachably connected to the bearing surface of the track link body by at least one of brazing and soldering
Implementation Method 3
The replaceable rail includes a brazing or soldering surface that is detachably connected to the bearing surface of the track link body by at least one of brazing and soldering
Data Source
AI summary
A composite track link is provided that has a body and a replaceable rail brazed or soldered together to provide a metallurgical bond between the track link body and the rail such that the rail may be removed and replaced by heating the track link or the brazing or soldering filler metal when the rail becomes worn. This process enables the rail to be separated from the body of the track link so a new rail can be brazed or soldered to the body of the track link. As a result, track links or bodies of track links may outlast the rails by multiple use cycles. Further, the body and rail may be formed of different materials.