Rolled and Folded Lip for Excavator Bucket Weldability
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Solution Overview
Problem
Current bucket lips for large earthmoving equipment, such as rope shovel machines and front excavators, are manufactured using cast materials with low weldability and hardness, making repairs difficult and affecting durability.
Innovation Solution
A rolled and folded lip made from stainless steel with improved weldability and hardness, utilizing rolled steel plates up to 3,000 mm wide and 12,000 mm long, and 250 mm thick, with flow characteristics between 600 and 900 MPa, is produced using a folding process and finishing techniques like drilling and oxy-cutting, and a hardened wear-resistant steel layer is applied for enhanced durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cast materials are used for bucket lips, then the manufacturing process is simple, but the weldability and hardness are low making repairs difficult
Solution Approach 1:
The patent changes the material parameters by transitioning from cast material to rolled steel plates with specific flow characteristics (600-900 MPa). This parameter change improves weldability while maintaining manufacturing feasibility through the folding process
Solution Approach 2:
The patent applies a hardened wear-resistant steel layer on the rolled lip, creating a composite structure that combines the ductility and weldability of rolled steel with the hardness and wear resistance of the hardened surface layer
2Ease of manufacture
If cast materials are used for bucket lips, then the manufacturing process is simple, but the durability is affected due to low hardness
Solution Approach 1:
The patent creates a composite structure by applying a hardened wear-resistant steel layer on the rolled lip. This combination provides both the durability needed for heavy-duty applications and the base material properties for good weldability
Solution Approach 2:
The patent changes the surface hardness parameter through the application of hardened steel layer, while the base rolled steel maintains its original properties for welding and forming
3Ease of repair
If rolled steel plates are used instead of cast materials, then weldability and hardness are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent uses folding operations to create the curved and contoured shapes needed for the lip. This allows the complex geometry to be achieved through forming operations on rolled plates rather than through complex casting or machining processes
Solution Approach 2:
The patent performs preliminary folding and shaping operations on the rolled steel plates before final assembly. This preliminary action simplifies the overall manufacturing process by preparing the material in advance for easier welding and installation
4Object-affected harmful factors
If rolled steel plates with high flow characteristics are used, then the lip becomes more resistant to abrasion, but the material selection and processing become more complex
Solution Approach 1:
The patent specifies rolled steel plates with flow characteristics between 600-900 MPa, optimizing the material parameters for both abrasion resistance and formability. This controlled parameter change balances performance requirements with manufacturing capabilities
Solution Approach 2:
The patent applies a hardened wear-resistant steel layer on the rolled lip, creating a composite structure where the base material provides ductility and the surface layer provides enhanced abrasion resistance
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 results in a lip with higher weldability and resistance to abrasion, facilitating easier repairs and extending the component's lifespan while maintaining or reducing weight and thickness compared to standard cast lips.
Implementation Method 1
A rolled and folded lip made from stainless steel with improved weldability and hardness
Implementation Method 2
a hardened wear-resistant steel layer is applied for enhanced durability
Data Source
AI summary
A rolled lip for rope shovel machine buckets and for excavator buckets of high hardness and improved weldability is provided. The rolled lip is folded and used in buckets with capacities above 25 m3. The lip is made of rolled steel plates of up to 3,000 mm wide and 12,000 mm long and up to 250 mm thick, wherein the steel has flow characteristics between 600 and 900 MPa. The noses and holes used to build the lip are drilled and the shape of the noses is provided by templates or gauges. A method for manufacturing such a rolled lip is also provided.