Sealed Hydraulic Tank With Expansion Bladder for Mining Shovels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Mining shovels face downtime due to contamination from dusty and moist environments, which affects hydraulic systems prone to contamination, leading to reduced operational time and increased maintenance needs.
Innovation Solution
A sealed hydraulic tank system comprising an upper and lower tank, expansion bladder, and filtering system with baffles and apertures to filter contaminants, ensuring cleanliness and efficient operation by minimizing air and moisture ingress and optimizing fluid flow and filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydraulic systems are used in mining shovels, then operational efficiency is improved, but contamination from dust and moisture reduces reliability
Solution Approach 1:
The patent employs a sealed tank system with flexible expansion bladders that create a physical barrier between the hydraulic fluid and the contaminated environment. The bladder expands and contracts with fluid level changes while maintaining hermetic sealing, preventing dust and moisture ingress while allowing the hydraulic system to operate efficiently in harsh mining conditions
Solution Approach 2:
The tank system creates a protected, inert environment for the hydraulic fluid by sealing it within a closed system that excludes the contaminated external atmosphere. This isolated environment maintains fluid cleanliness and prevents contamination-related failures, ensuring both high productivity and reliability
2Productivity
If hydraulic systems operate continuously, then productivity increases, but contamination leads to increased maintenance needs
Solution Approach 1:
The system incorporates preliminary filtration through baffles and filters before fluid circulates through the hydraulic system. This proactive contamination prevention approach removes particles and moisture before they can cause component wear or failure, enabling continuous operation with reduced maintenance intervals
Solution Approach 2:
The expansion bladder maintains a hermetic seal that prevents external contaminants from entering the hydraulic system during continuous operation. This protective barrier ensures the fluid remains clean throughout extended operational periods, reducing the frequency of maintenance and repairs
3Quantity of substance
If air is exchanged with the tank system, then fluid expansion is accommodated, but moisture and dust ingress contaminate the hydraulic fluid
Solution Approach 1:
The expansion bladder acts as a flexible, impermeable membrane that accommodates fluid volume changes through expansion and contraction while maintaining a hermetic seal. This eliminates the need for air-breathing openings, preventing moisture and dust from entering the hydraulic fluid during volume fluctuations
Solution Approach 2:
The bladder serves as an intermediary between the hydraulic fluid and the external environment, allowing volume changes to be accommodated without direct exposure to contaminated air. The bladder mediates the volume change requirement while blocking harmful contaminants, solving both needs simultaneously
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 system enhances operational time and reduces maintenance by maintaining hydraulic fluid cleanliness, preventing contamination, and ensuring efficient operation in harsh mining environments.
Implementation Method 1
an expansion bladder coupled to the upper tank through an air transfer tube located exterior to the upper tank, such that air can be exchanged between the tank system and the bladder when the cylinder is activated
Implementation Method 2
The upper tank can include a filter for filtering hydraulic fluid, also referred to herein as oil, in the upper tank
Implementation Method 3
The upper tank can also include a plurality of baffles partitioning the upper tank into a plurality of compartments, wherein at least one of the baffles includes an aperture to direct a flow of fluid through the tank
Implementation Method 4
a cooler system connected between the upper and lower tanks, wherein when the hydraulic cylinders are activated, hot oil is returned to the upper tank and is transmitted through the cooler system and to the lower tank
Data Source
AI summary
A sealed hydraulic tank system for a mining shovel (10) includes an upper tank (68) and a lower tank (70). An air bladder (69) system is coupled to the upper tank to exchange air between the tank system and the bladder. The tanks include baffles (100,102,104,106,108) which filter the hydraulic fluid and which direct fluid flow along an elongated path to allow for de-aeration of the oil in the tank.