Sludge Collector Roller Unit Prevents Flight Reversal

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Solution Overview

Problem

Existing chain flight type sludge collectors in large settling basins face issues such as frequent chain breakage, durability deterioration due to reversed flights, and wear strip deformation, leading to operational disruptions and increased construction time.

Innovation Solution

The implementation of an attachment-integrated roller unit and carrier roller units, which include urethane rollers and shaft fixing members, to prevent flight reversal and reduce friction, combined with a return rail guide to prevent derailment, addresses these issues by maintaining chain alignment and reducing operational load.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If a non-metallic conveyor chain is used in a large settling basin, then the chain durability is improved, but the flight may be reversed due to full width loading

Engineering Contradiction:

Improvechain durabilityVSAvoidflight orientation

Core Design Contradiction:

Duration of action of stationary objectVSStability of the object's composition

Solution Approach 1:

A guide rail is introduced as an intermediary component between the flight and the chain. The guide rail prevents the flight from reversing by providing a physical constraint that guides the flight's movement, while the chain continues to provide the driving force. This mediator resolves the conflict between chain durability and flight orientation stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Shape

If the flight is transported on a lower portion with a shoe and wear strip, then the flight is supported at a certain distance from the bottom, but friction force generates and deteriorates part durability

Engineering Contradiction:

Improveflight positionVSAvoidpart durability

Core Design Contradiction:

ShapeVSDuration of action of stationary object

Solution Approach 1:

The mechanical contact system consisting of shoe and wear strip is replaced with a roller unit that rotates. This substitution changes the friction mechanism from sliding friction to rolling friction, significantly reducing the friction force and improving the durability of both the flight support components and the wear strip.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Shape

If wear strip is constructed on the bottom, then the flight is supported properly, but construction time increases and wear strip deformation occurs

Engineering Contradiction:

Improveflight supportVSAvoidconstruction period

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The wear strip construction is segmented into modular sections that can be pre-assembled and then quickly installed. This segmentation allows for faster construction while maintaining proper flight support. Additionally, the modular design makes it easier to replace deformed sections without reconstructing the entire wear strip.

Inventive Principle:

Principle #1Segmentation

4Shape

If wear strip deforms due to friction and wastewater, then flight replacement is required, but operational disruption increases

Engineering Contradiction:

Improvewear strip integrityVSAvoidoperational stability

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The sliding contact between shoe and wear strip is replaced with a rolling contact system. This substitution dramatically reduces friction and the associated deformation of the wear strip, eliminating the need for frequent wear strip replacement and maintaining operational stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

5Productivity

If chain flight method is used in large settling basin, then sludge collection is achieved, but frequent chain breakage occurs

Engineering Contradiction:

Improvesludge collection efficiencyVSAvoidchain reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A guide rail is introduced as a mediator to prevent flight reversal and misalignment. This intermediary component reduces the lateral forces and stress on the chain, preventing frequent chain breakage while maintaining effective sludge collection in large settling basins.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This solution enhances chain durability, reduces power consumption, ensures stable operation, and allows for faster construction by eliminating the need for bottom wear strip construction, thereby addressing the problems of chain breakage and wear strip deformation.

Implementation Method 1

The implementation of an attachment-integrated roller unit and carrier roller units, which include urethane rollers and shaft fixing members, to prevent flight reversal and reduce friction

Methodology Applied

Scientific EffectRolling friction: Friction

Implementation Method 2

shaft fixing members to prevent flight reversal and reduce friction

Methodology Applied

Scientific EffectMechanical constraint: Mechanical Fastener

Data Source

PatentUS11123659B2Sludge collector

Publication Date: 2021.09.21 LINKON TECH

AI summary

The present disclosure relates to a sludge collector including: a plurality of flights collecting sludge in a settling basin; a chain connected to the plurality of flights to move the flights; and an attachment-integrated roller unit detachably coupled to an attachment connected to the flights, and preventing the flights from being reversed when the flights are operated.