Self-Aligning Monorail Beam Connections for Automated Installation
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Solution Overview
Problem
Existing monorail systems for mines are cumbersome to install, requiring complex connections and chains or bolts, which hinder efficient and automated installation.
Innovation Solution
A connection system for monorail beams featuring upper and lower connection means with interlocking mechanisms, including a female slot and male locking protrusion, allowing for swift alignment and secure attachment, and a biasing mechanism to prevent unintentional disconnection, facilitating automated installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional monorail connection systems using chains, bolts, or transverse pins are used, then the monorail beams can be connected and suspended, but the installation becomes cumbersome and time-consuming
Solution Approach 1:
The connection system is divided into separate modular components: a support member with support surface, a female interlocking means with slot and latch, and a male interlocking means with locking protrusion. These segmented components can be independently manufactured and assembled, enabling quick connection without complex chains or bolts.
Solution Approach 2:
The connection system is designed to be self-aligning and self-locking. The support surface automatically supports the second beam from below during connection, the slot guides the locking protrusion into place, and the latch with biasing means automatically engages to secure the connection, eliminating the need for manual alignment or additional fastening operations.
2Reliability
If complex interlocking mechanisms with multiple components are used to ensure secure beam connection, then connection reliability improves, but device complexity increases
Solution Approach 1:
Multiple functions are merged into single components: the support member combines support surface and interlocking features; the female interlocking means integrates slot, latch, and biasing means; the male interlocking means combines locking protrusion with beam attachment features. This merging reduces the number of separate parts while maintaining connection security.
Solution Approach 2:
The latch is designed to be movably attached, transitioning between locking and unlocking positions. The biasing means provides dynamic force to maintain the latch in the locking position, creating a simple yet reliable dynamic locking mechanism that ensures connection security without complex static structures.
3Manufacturing precision
If manual alignment and connection of monorail beams is performed, then connection precision can be achieved, but installation productivity decreases
Solution Approach 1:
The support surface is positioned to extend out from the first beam along its longitudinal axis, creating a natural support level that automatically aligns the second beam horizontally. This equipotential support arrangement eliminates the need for manual alignment adjustments while maintaining precise beam positioning.
Solution Approach 2:
The slot acts as an intermediary guide that receives and guides the locking protrusion into the correct position. This intermediary feature automatically aligns the male and female interlocking means during connection, achieving precise alignment without manual intervention and enabling faster installation.
4Loss of time
If automated installation of monorail beams is implemented, then installation time is reduced, but the connection system requires simpler interlocking mechanisms that may compromise connection strength
Solution Approach 1:
The locking protrusion is nested within the slot, and the latch is nested within the female interlocking means. This nested arrangement allows the components to be compact yet robust, providing strong mechanical interlocking that can withstand automated handling forces while maintaining connection strength.
Solution Approach 2:
The biasing means is pre-configured to automatically push the latch into the locking position when the male and female interlocking means engage. This preliminary action ensures the connection is securely locked before the automated installation process completes, maintaining connection strength without requiring complex automated locking mechanisms.
Data Source
Figure 1
Figure 2~3
AI summary
A connection system for connecting a first monorail beam to a second monorail beam, wherein the connection system comprises upper connection means and lower connection means, wherein the lower connection means is configured to support the second beam from below, and wherein the upper connection means is configured to be connected by movement of the second monorail beam downwards relative to the first monorail beam and wherein the upper connector limits longitudinal relative movement between the first monorail beam and the second monorail beam when connected.