Surface-Hardened Studded Chain for Pipe Cleaning
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Solution Overview
Problem
Existing pipe cleaning tools require laborious and expensive jointing of hard metal pieces to chains, which is time-consuming and costly, and often result in tools that are not cost-effective for manufacturing and maintenance.
Innovation Solution
Using anti-skid chains with surface-hardened studs, where the studs are welded or melted onto the chain links, providing high surface hardness without compromising the chain's toughness, eliminating the need for hard metal pieces and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hard metal pieces are soldered to chain links to achieve high hardness for cleaning efficiency, then the cleaning efficiency and service life are improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent changes the material parameters of the chain links themselves by incorporating high-hardness materials (such as carbide or ceramic particles) directly into the chain link composition or surface treatment, eliminating the need for separate hard metal pieces. This parameter change achieves high cleaning efficiency while simplifying the structure by removing the jointing requirement.
Solution Approach 2:
The patent merges the functions of the chain link and the hard metal piece into a single integrated component. The hard material is either embedded within or forms part of the chain link structure itself, combining the structural function of the chain with the cleaning function of the hard material, thereby eliminating the complex soldering joint.
2Reliability
If hard metal pieces are soldered to chain links to maintain toughness of the chain, then the chain durability is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent modifies the material composition and heat treatment parameters of the chain links to achieve both toughness and hardness within the same component. By controlling the material parameters (such as using alloy steels with specific carbon content and applying heat treatment processes), the chain maintains its toughness while providing sufficient hardness for cleaning applications, all in a single manufacturing process without time-consuming jointing operations.
3Strength
If expensive special solders are used to join hard metal pieces to chains, then the joint strength is improved, but the manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the separate hard metal piece and the expensive special solder from the system. Instead, the hard material is integrated directly into the chain link structure through casting, forging, or surface treatment processes, removing the need for any joining operation and associated expensive materials, thereby significantly reducing manufacturing cost while maintaining joint strength.
Solution Approach 2:
The patent changes the material parameters of the chain link to inherently provide both the structural integrity and the hard surface properties previously requiring separate components and expensive solders. By selecting appropriate alloy compositions and heat treatment parameters, the chain link achieves the necessary strength without any additional joining materials.
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 solution allows for faster and less expensive manufacturing of cleaning devices, maintaining the chain's toughness while achieving high surface hardness, thus enhancing cleaning efficiency and reducing wear without the need for expensive materials.
Implementation Method 1
the studs are welded or melted onto the chain links
Implementation Method 2
the studs are welded or melted onto the chain links
Implementation Method 3
the use of hard metal pieces is unnecessary, if the studded chains manufactured from iron or steel are surface hardened, for example, by carbonizing, which affords a high surface hardness, but maintains the toughness of the metal in the inner parts
Data Source
AI summary
The cleaning device is for cleaning the inner surface of pipes. The method is for manufacturing the cleaning device and the use is of a vehicle anti-skid chain for cleaning the inner surface of a pipe. The cleaning device has a sleeve, to which are attached studded chains composed of steel links and surface hardened.