Storage Wagon Deflector Plate for Continuous Bulk Material Handling
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Solution Overview
Problem
Existing storage wagons for bulk material lack the capability for intermediate storage, leading to disruptions in continuous processes like ballast cleaning, as they require halting the material flow to uncouple wagons for emptying.
Innovation Solution
A storage wagon design featuring a bottom conveyor belt, a transfer conveyor belt, and an auxiliary conveyor belt with a pivotable deflector plate that allows for temporary storage and height adjustment of bulk material, enabling continuous operation and uniform transfer to subsequent wagons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If bulk material is discharged from the auxiliary conveyor belt onto the bottom conveyor belt while the latter is moved at slow storage speed, then intermediate storage of bulk material is enabled, but the device complexity increases due to the additional deflector plate mechanism
Solution Approach 1:
The deflector plate acts as an intermediary device between the auxiliary conveyor belt and the bottom conveyor belt. It redirects bulk material from the auxiliary conveyor belt onto the moving bottom conveyor belt, enabling intermediate storage functionality without requiring direct coupling between the two conveyor systems. This mediator mechanism allows continuous operation by decoupling the storage function from the transfer function.
Solution Approach 2:
The bottom conveyor belt is designed to move at a slow storage speed in the opposite direction to the conveying direction, creating a dynamic storage zone. This dynamic movement allows bulk material to be accumulated and stored temporarily on the bottom conveyor belt while it continues to move, enabling uncoupling of the storage wagon without halting the continuous accrual of bulk material.
2Manufacturing precision
If the deflector plate is used to limit the height of bulk material by forming a gap, then manufacturing precision of material layer height is improved, but the device complexity increases due to the adjustable mechanism
Solution Approach 1:
The deflector plate is designed with adjustable parameters, specifically its vertical position relative to the bottom conveyor belt. By changing the vertical position parameter of the deflector plate, the gap between the deflector plate and the bottom conveyor belt is controlled, which directly determines the height of the bulk material layer. This parameter adjustment enables precise control of material layer height without complex additional mechanisms.
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
Enables continuous operation by allowing intermediate storage and uniform material transfer, improving the efficiency of bulk material storage and handling processes without halting the material flow.
Implementation Method 1
the deflector plate is designed to be pivotable about a pivot axis relative to the loading container for changing a deflection angle enclosed with a conveying plane of the bottom conveyor belt
Implementation Method 2
a bottom conveyor belt extending in the longitudinal direction of the wagon
Implementation Method 3
a transfer conveyor belt for passing on stored bulk material in a conveying direction, the transfer conveyor belt adjoining a transfer end of the bottom conveyor belt
Data Source
AI summary
A storage wagon (1) for bulk material (2) has, above the transfer end (9) of a bottom conveyor belt (4) and underneath a discharge end (15) of an auxiliary conveyor belt (14), a deflector plate (17) extending perpendicularly to the longitudinal direction (3) of the wagon. The deflector plate (17) is designed to be pivotable about a pivot axis (18) relative to the loading container (5) for changing a deflection angle α enclosed with a conveying plane (19) of the bottom conveyor belt (4).