Winch Drum Tension Isolation via Locking Mechanism
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Solution Overview
Problem
In underground mining, heavy winches used for conveyor systems can experience park brake seizures during emergency stops, leading to overheating and trapped energy, posing risks to operators when attempting repairs or replacements.
Innovation Solution
A conveyor system with a winch drum featuring an outwardly extending flange with spaced holes and a locking mechanism that allows the winch drum to be locked in place, preventing rotation and isolating tension, thereby allowing safe energy release and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the park brake is used to provide emergency braking force, then the conveyor can be stopped in emergency situations, but the brake may overheat and seize, trapping stored energy and creating safety hazards
Solution Approach 1:
The invention extracts the tension isolation function from the park brake system by introducing a separate locking mechanism with a locking member that can independently secure the winch drum. This removes the harmful braking function from the energy storage path, preventing the brake from being exposed to dynamic braking loads that cause overheating and seizure.
Solution Approach 2:
The locking mechanism acts as an intermediary between the winch drum and the park brake. By inserting this intermediate locking device, the system can isolate tension in the conveyor from the brake, allowing the brake to perform its emergency stopping function without being subjected to the harmful trapped energy that causes overheating.
2Reliability
If the park brake seizes, then it traps stored energy in the conveyor, but this creates a safety risk for operators attempting repairs
Solution Approach 1:
The locking mechanism provides preliminary action by allowing operators to proactively lock the winch drum in place before attempting any maintenance work. The locking member can be positioned in engagement with the flange holes in advance, securing the drum and isolating tension before operators approach the brake assembly for repairs.
Solution Approach 2:
The locking mechanism provides preliminary anti-action by counteracting the trapped energy threat before maintenance begins. By pre-engaging the locking member with the flange, the system neutralizes the hazardous stored energy in the conveyor belt, preventing it from causing injury during repair operations.
3Ease of operation
If a locking mechanism is added to prevent drum rotation, then maintenance safety is improved, but device complexity increases
Solution Approach 1:
The locking mechanism is segmented into distinct, simple components: a locking member with a distal end for engagement, a housing containing the locking member, and spacing elements. This segmentation allows each component to perform its specific function independently, simplifying the overall design while maintaining safety effectiveness.
Solution Approach 2:
The locking mechanism is designed to be self-servicing through the spring element that automatically biases the locking member toward engagement with the flange holes. This self-energizing feature reduces the need for complex actuation systems and makes the locking function inherently reliable without requiring additional power sources or complex control systems.
Data Source
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AI summary
A winch drum tension isolation system includes a winch drum including an outwardly extending flange, the flange including a plurality of holes spaced along the flange. The winch drum tension isolation system also includes a locking mechanism positioned proximate the winch drum and including a locking member engageable with the flange. The locking member is movable between a first position, in which the locking member is received in one of the plurality of holes to prevent rotation of the winch drum, and a second position, in which the locking member is spaced apart from the flange to permit rotation of the winch drum.