Segmented Track Slider Mounting Plate for Wear Reduction

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Solution Overview

Problem

Current track sliders for heavy equipment, particularly in oilsands applications, require frequent maintenance or replacement after 4,000 to 6,000 operating hours due to wear and cracking, leading to extended downtime for disassembly and replacement of track chains.

Innovation Solution

A roller frame assembly with a unique design featuring a sprocket and idler attachment portions, side frame members, and slider mounting plates with an inner gusset plate and beveled surfaces, which distributes stress and reduces wear, allowing for improved serviceability and extended lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional track sliders are used in harsh environments, then the equipment can operate, but the track sliders become worn or cracked after 4,000 to 6,000 hours requiring maintenance

Engineering Contradiction:

Improvetrack slider durabilityVSAvoidoperational hours before maintenance

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The track slider is divided into multiple mounting plates (front slider mounting plate with front and rear portions, rear slider mounting plate, and intermediate slider mounting plates) that can be independently attached to the top frame member. This segmentation allows individual plates to be replaced without replacing the entire track slider assembly, extending operational life while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting plates are designed with pre-formed attachment features including weld tabs and mounting holes that facilitate preliminary attachment to the frame member. The inner gusset plate is pre-positioned to provide structural support before the track slider components are fully assembled, preventing wear and cracking issues before they occur.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If track sliders are replaced frequently to maintain reliability, then equipment reliability improves, but downtime increases due to disassembly and replacement requirements

Engineering Contradiction:

Improvetrack slider reliabilityVSAvoiddowntime for maintenance

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The track slider assembly is segmented into multiple independently replaceable mounting plates attached to the top frame member. When wear or damage occurs, only the affected mounting plate needs to be replaced rather than the entire track slider assembly, significantly reducing maintenance downtime while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting plates are designed as replaceable components that can be discarded when worn and replaced with new or refurbished plates. The inner gusset plate and other structural components are recovered and retained, reducing the frequency of complete assembly replacements and minimizing downtime.

Inventive Principle:

Principle #34Discarding and recovering

3Strength

If mounting hardware and plates are used to attach track sliders, then the track sliders can be secured, but the mounting hardware experiences wear, cracks, and weld weakening

Engineering Contradiction:

Improvemounting attachment strengthVSAvoidmounting hardware reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The mounting plates are pre-formed with integrated weld tabs and attachment features that are prepared in advance for secure attachment to the top frame member. The inner gusset plate is pre-positioned to provide structural reinforcement before final assembly, ensuring strong initial attachment that resists wear and welding degradation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mounting assembly uses composite construction combining the top frame member with multiple mounting plates and an inner gusset plate. This composite structure distributes mechanical and thermal stresses across multiple materials and components, preventing localized wear, cracks, and weld weakening that would occur in single-material constructions.

Inventive Principle:

Principle #40Composite materials

4Reliability

If the inner gusset plate is attached underneath the top frame member with the rear portion of the front slider mounting plate above the gusset plate, then stress is distributed and wear is reduced, but the device complexity increases

Engineering Contradiction:

Improvetrack slider lifespanVSAvoidmounting assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mounting assembly is segmented into distinct components including the top frame member, inner gusset plate, front slider mounting plate with separate front and rear portions, and intermediate mounting plates. This segmentation allows each component to be optimized for its specific function while distributing stress to extend lifespan, with the added benefit that individual components can be replaced independently.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12187365B2Track slider design for an electric rope shovel

Publication Date: 2025.01.07 CATERPILLAR GLOBAL MINING LLC

AI summary

A track slider mounting plate kit includes a first shark fin configured mounting plate including a first bottom mounting surface, a first beveled surface extending from the first bottom mounting surface, and a second beveled surface that extends from the first beveled surface, forming a first oblique angle with the second beveled surface. A track slider is attached to the first shark fin configured mounting plate that has a top surface extending from the rear surface toward the front surface defining a top surface radius of curvature ranging from 2200 mm to 2600 mm.