Rotary type material reducing tool

Abstract

A rotary subtracting tool includes a drum, a ferrule, and a hammer. The drum has an outer surface extending about an axis of rotation of the drum. The drum has a first opening defined in the outer surface of the drum. The ferrule is received in the first opening. A first portion of the ferrule extends into the drum and a flange of the ferrule extends beyond the first opening and along the outer surface of the drum. The hammer extends through the ferrule and into the drum. The hammer has an exposed portion. The flange of the hoop sleeve and the outer surface of the roller are welded together.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to co-pending U.S. Provisional Patent Application No. 63 / 512,197, filed on July 6, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to material reducing machines, such as grinders, shredders and chippers. Background Art

[0004] Subtractive machines are used to reduce the size of materials such as waste. Exemplary waste includes waste wood (e.g., trees, brushes, stumps, pallets, railroad sleepers, etc.), peat moss, paper, wet organic materials, industrial waste, garbage, construction waste, etc. Typical subtractive machines such as grinders, chippers, or shredders include a rotor on which a plurality of subtractors (e.g., teeth, cutters, blades, grinding tips, chisels, etc.) are mounted. The subtractors are typically mounted around the periphery of the rotor and are supported by the rotor around the axis of rotation of the rotor when the rotor rotates. During the subtractive operation, the rotor is rotated and the waste is fed into the vicinity of the rotor so that the contact between the subtractors and the waste provides a subtractive or comminution effect on the waste.

[0005] Grinding machines and chippers are typically configured to reduce material by direct impact of the reducer on the material. In contrast, shredders are typically configured such that the reducer operates in conjunction with a comb-like structure that intermeshes with the reducer as the rotor rotates. In typical shredder operation, the reducer forces the material fed into the shredder through the comb-like structure as the rotor rotates, thereby providing a shredding action. It should be understood that during the reduction operation, the rotor of the grinding machine and the rotor of the chipper are typically operated at a higher rotational speed than the rotor of the shredder.

[0006] The subtractive rotor of a subtractive machine is subject to extreme loads. Despite the different loads, due to the different speeds, the subtractive rotor must be designed to be robust to withstand the loads. In addition, the subtractive rotor and the components to which it is attached (e.g., hammers and cutters) may experience high wear rates, especially if the waste material is abrasive. For this reason, the attached components are usually replaceable. Summary of the invention

[0007] In an independent aspect, a method of assembling a rotary subtractive tool includes providing a drum having an outer surface extending about an axis of rotation of the drum. Assembling a band from the outside of the drum into a first opening in the outer surface of the drum until a portion of the band extends into the drum and a flange of the band extends beyond the first opening and along the outer surface of the drum. Welding the flange of the band to the outer surface of the drum. Inserting a hammer through the band so that a portion of the hammer remains exposed. Securing the hammer to the band.

[0008] In another independent aspect, a rotary subtractive tool has a drum, a hoop, and a hammer. The drum has an outer surface extending around an axis of rotation of the drum. The drum has a first opening defined in the outer surface of the drum. The hoop is received in the first opening. A first portion of the hoop extends into the drum, and a flange of the hoop extends beyond the first opening and extends along the outer surface of the drum. The hammer extends through the hoop and into the drum. The hammer has an exposed portion. The flange of the hoop is welded to the outer surface of the drum. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a rear perspective view of a subtractive machine according to one embodiment of the present disclosure.

[0010] Figure 2 yes Figure 1 Another rear perspective view of the subtractive machine.

[0011] Figure 3 yes Figure 1 Top view of the subtractive machine.

[0012] Figure 4 is a front perspective view of a subtractive rotor system according to one embodiment of the present disclosure.

[0013] Figure 5 yes Figure 4 Rear perspective view of the subtractive rotor system.

[0014] Figure 6 yes Figure 4 Top view of the subtractive rotor system.

[0015] Figure 7 yes Figure 4 A front perspective view of the subtractive rotor system with the end caps removed.

[0016] Figure 8 yes Figure 7 End view of the subtractive rotor system.

[0017] Fig. 9 yes Figure 4 A perspective view of the drum of a subtractive rotor system.

[0018] Fig.10 yes Figure 4 Perspective view of the wear plates of a subtractive rotor system.

[0019] Fig.11 yes Fig.10 Top view of the wear plate.

[0020] Fig.12 yes Figure 4 A perspective view of the collar of a subtractive rotor system.

[0021] Fig.13 yes Fig.12 A top view of the hoop.

[0022] Fig.14 yes Fig.12 Side view of the hoop.

[0023] Fig.15 yes Fig.12 Bottom perspective view of the hoop.

[0024] Fig.16 yes Fig.12 A side view of a cuff with an extension.

[0025] Fig.17 yes Fig.16 End view of the hoop.

[0026] Fig.18 yes Fig.16 Bottom perspective view of the hoop.

[0027] Fig.19 is along Fig.17 A cross-sectional view of the cuff taken along line 19-19.

[0028] Fig. 20 yes Figure 4 Perspective view of the rotor weldment of the subtractive rotor system.

[0029] Fig.21 yes Fig. 20 End view of the rotor weldment.

[0030] Fig. 22 yes Figure 7 Detailed view of the subtractive rotor system.

[0031] Fig.23 yes Fig. 22 Exploded end view of the subtractive rotor system.

[0032] Fig.24 yes Fig.23 Detailed view of a portion of an exploded end view.

[0033] Fig.25 yes Figure 7 Exploded perspective view of the subtractive rotor system.

[0034] Fig.26 is along Figure 6 A cross-sectional view of the subtractive rotor system taken along line 26-26.

[0035] Fig. 27 yes Fig.26 Detailed view of a portion of a cross section.

[0036] Fig.28 According to another embodiment of the present disclosure Fig.26 Detailed view of a portion of a cross section. DETAILED DESCRIPTION

[0037] Before any embodiment, example, aspect or feature is explained in detail, it should be understood that these embodiments, examples, aspects and features are not limited in their application to the details of construction and arrangement of components set forth in the following description or illustrated in the following figures. Other embodiments, examples, aspects and features are also possible and can be practiced or implemented in various ways. It should also be understood that the phrases and terms used herein are for descriptive purposes and should not be considered limiting.

[0038] Figures 1 to 3 A subtractive machine 20 is shown, which is an example of a type of subtractive machine in which a subtractive rotor according to the principles of the present disclosure may be incorporated. The rotary subtractive machine 20 is shown as a shredder, but it should be understood that aspects of the present disclosure are also applicable to other types of subtractive machines such as grinders and chippers. In one optional example, the rotary subtractive machine 20 can be a relatively slow shredder, wherein the rotor operates at a speed of less than or equal to 40 revolutions per minute during the shredding operation (described in detail below). It should be appreciated that the slower operating rotor speed reduces the importance of maintaining rotor balance and therefore allows greater flexibility in selecting different subtractive rotor components and configurations. In another optional example, the rotary subtractive machine 20 can be a relatively fast grinder or chipper, wherein the rotor operates at a speed greater than 40 revolutions per minute during the shredding operation.

[0039] The rotary reducing machine 20 includes a main frame defining a reducing box 22, in which a reducing rotor 24 is positioned. The reducing rotor 24 is mounted to rotate about a central axis 26 within the reducing box 22. The reducing rotor 24 may be rotatably mounted to the reducing box 22 by bearings. A plurality of reducers 28 are mounted on the outside of the reducing rotor 24. When the reducing rotor 24 rotates about the central axis 26, the reducers 28 are carried by the reducing rotor 24 along a circular reducing path around the central axis 26. The rotary reducing machine 20 includes a hopper 30 located above the reducing rotor 24, which allows the material to be reduced to be fed into the reducing box 22. The hopper 30 optionally includes a screen (not shown) mounted below the reducing rotor 24 for controlling the size of the reduced product output from the reducing box 22. The rotary reducing machine 20 may also include a shredder comb 32 mounted in the reducing box 22. The chopping comb 32 includes a plurality of comb teeth, and the chopping comb 32 is positioned relative to the reduction rotor 24 so that, as the reduction rotor 24 rotates around the central axis 26, the reducer 28 of the reduction rotor 24 engages with the comb teeth of the chopping comb 32. In other words, as the reduction rotor 24 rotates, the reducer 28 passes between the corresponding comb teeth of the chopping comb 32. The rotary reduction machine 20 also includes a power system (not shown) for driving the reduction rotor 24 to rotate around the central axis 26. The power system may include a prime mover (e.g., an engine) that provides the power required to drive the reduction rotor 24 to rotate. The power system may also include a transmission device for transmitting power from the prime mover to the reduction rotor 24. The power may be transmitted in the form of torque. The rotary reduction machine 20 may also include one or more conveyors 34 for transferring the reduction products discharged from the reduction box 22 away from the reduction box 22.

[0040] In operation of the rotary reducer 20, the material desired to be reduced is fed into the reduction box 22 through the hopper 30. Within the reduction box 22, the reduction rotor 24 is rotated about the rotation axis 26 by the power system. The material fed into the reduction box 22 is impacted by the reducers 28 of the rotating rotor 24, and the material is forced through the shredder comb 32 by the reducers 28, thereby causing the material to be reduced in size by shredding. The shredded material forced through the shredder comb 32 can be deposited on a conveyor 34 and transferred by the conveyor 34 to a collection location, such as a truck bed or a pile on the ground. If the hopper 30 includes a grading screen below the reduction rotor 24, the material that has been reduced to a small size sufficient to travel through the screen is deposited on the conveyor 34, and the remaining material is recycled back to the reduction box 22 through the reduction rotor 24 for further processing until the material is small enough to travel through the screen.

[0041] Figures 4 to 8 A subtractive rotor system 50 (eg, Fig. 9The subtractive rotor system 50 can be integrated into a subtractive machine such as the rotary subtractive machine 20, for example, by using a subtractive rotor system 50 (shown separately in FIG. 1 ). Thus, the subtractive rotor system 50 is configured as a rotary subtractive tool. The subtractive rotor system 50 can rotate about a central rotation axis 54. The subtractive rotor system 50 can be installed in a subtractive machine (e.g., in a subtractive box 22 of a rotary subtractive machine 20), and when the subtractive rotor system 50 is installed in the rotary subtractive machine 20, the rotation axis 54 of the subtractive rotor system 50 coincides with the central axis 26 of the rotary subtractive machine 20. The rotation axis 54 of the subtractive rotor system 50 also extends through the center of the drum 52 to form the rotation axis of the drum 52.

[0042] The reduced material rotor system 50 includes: a rotor weldment 56 ( Fig. 20 ) of a portion of the roller 52 ( Fig. 9 ), a hammer 58 removably coupled to the rotor weldment 56, and a reducer 62 (e.g., teeth, cutters, blades, etc.) removably coupled to the hammer 58. The subtractive rotor system 50 includes a first end cap 53 and a second end cap 55 opposite the first end cap 53, portions of the first end cap 53 and the second end cap 55 being removably coupled to the ends of the rotor weldment 56. In use, the subtractive rotor system 50 can be rotationally driven by a torque source (e.g., a power system) to rotate about a rotation axis 54. The first end cap 53 of the subtractive rotor system 50 is a driven end such that the first end cap 53 is connected to a torque source (e.g., a power system) and receives torque from the source. The second end cap 55 of the subtractive rotor system 50 is a mounting end configured to support the subtractive rotor system 50 in a subtractive machine (e.g., in a subtractive box 22).

[0043] The subtractive rotor system 50 rotates about the rotation axis 54 in a rotation direction 70. In the illustrated embodiment, when the first end cap 53 (e.g., Figure 4 The direction of rotation 70 is clockwise when viewing the subtractive rotor system 50 (as shown in FIG. 1 ). The hammers 58 are axially positioned along the subtractive rotor system 50 between the first end cap 53 and the second end cap 55. More specifically, each hammer 58 is located at a specified axial position along the length of the drum 52. When the subtractive rotor system 50 rotates about the rotation axis 54, the reducers 62 travel along a circular subtractive path about the rotation axis 54. In some embodiments, the reducers 62 can be integrally formed with the hammers 58.

[0044] Fig. 9The drum 52 is illustrated. The drum 52 is an elongated cylindrical structure having an outer surface 74 and an inner cavity 78. The outer surface 74 extends from a first end of the drum 52 to a second end of the drum 52. The first end of the drum 52 is adjacent to the first end cap 53, and the second end of the drum 52 is adjacent to the second end cap 55. The outer surface 74 also extends around the rotation axis 54.

[0045] The drum 52 also includes a plurality of openings 82 (e.g., collar locations) configured to receive the hammers 58 and additional support structures (described in detail below). The openings 82 extend from the outer surface 74 to the inner cavity 78. In the illustrated embodiment, the openings 82 have an oval shape, however, in other embodiments, the openings 82 may have a different elongated shape (e.g., rectangular).

[0046] The openings 82 include a first opening 82a, a second opening 82b, a third opening 82c, and a fourth opening 82d defined in the outer surface 74 of the drum 52. The openings 82 are grouped into axial groups spaced apart along the length of the drum 52. The first group of openings includes a first opening 82a and a second opening 82b. The first opening 82a and the second opening 82b are positioned at the same axial position along the drum 52. The first opening 82a and the second opening 82b are positioned radially opposite to each other so that the first opening 82a and the second opening 82b are spaced apart by 180 degrees. In other words, the first opening 82a and the second opening 82b are diametrically opposed on the drum 52. In the illustrated embodiment, each axial group of openings includes two openings 82 (e.g., the first opening 82a and the second opening 82b), but in other embodiments, the opening group may include more openings 82 spaced apart at equal intervals along the periphery of the drum 52. In some embodiments, the opening group may include only one opening.

[0047] The third opening 82c and the fourth opening 82d form a second group of openings that are similar to the first group of openings (e.g., the first opening 82a and the second opening 82b) and are axially spaced apart from the first group of openings. In the illustrated embodiment, the second group of openings is also angularly offset from the first group of openings. In the illustrated embodiment, the opening groups are offset by 60 degrees, however, in some embodiments, the angular offset may be more or less.

[0048] refer to Figures 4 to 8 and Figure 20 to Figure 22 The hammer 58 is removably coupled to the drum 52 via a collar (e.g., a mount or support). The subtractive rotor system 50 may include a plurality of collars 106 that removably couple the hammer 58 to the drum 52 and provide support to the hammer 58. Each collar of the plurality of collars 106 is at least partially received in one of the openings 82.

[0049] The plurality of cuffs 106 include a first cuff 106a and a second cuff 106b ( Fig.21 , Fig. 22 ). The first cuff 106a is at least partially received in the first opening 82a, and the second cuff 106b is at least partially received in the second opening 82b. In the illustrated embodiment, the first cuff 106a is coupled to and supports one end of the hammer, and the second cuff 106b is coupled to and supports the other end of the hammer. In the illustrated embodiment, the second cuff 106b is similar to the first cuff 106a, so only the first cuff 106a will be described in detail. In some embodiments, the second cuff 106b can be different from the first cuff 106a.

[0050] refer to Figures 12 to 19 , the first hoop 106a can be a single piece. The first hoop 106a can be a forged body. The first hoop 106a has an inner portion 118 (e.g., a first portion), an outer portion 122 (e.g., a second portion), and a hammer cavity 126 extending between the inner portion 118 and the outer portion 122. When the first hoop 106a is received in the opening 82a (e.g., positioned in the opening 82a or coupled to the opening 82a), the inner portion 118 extends into the drum 52, and the outer portion 122 extends along the outer surface 74 of the drum 52. In the illustrated embodiment, the inner portion 118 is smaller than the opening 82a, so that when the first hoop 106a is located in the opening 82a, there is a gap between the inner portion 118 and the opening 82a. In some embodiments, the inner portion 118 is the same size as the opening 82a, so that when the first hoop 106a is located in the opening 82a, the inner portion 118 is flush with the opening 82a.

[0051] The outer portion 122 includes a flange 150 (e.g., an overhang). The flange 150 is the widest portion of the first cuff 106a, so that the flange 150 defines the outer perimeter of the first cuff 106a. The outer perimeter is larger than the perimeter of the opening 82a. In the illustrated embodiment, the flange 150 extends continuously along the entire perimeter of the first cuff 106a. In some embodiments, the flange 150 may extend only along a section of the first cuff 106a. For example, the flange 150 may extend only along the end of the first cuff 106a, or the flange 150 may be formed by intermittent segments spanning along the perimeter of the cuff 106a.

[0052] The flange 150 and the outer perimeter of the first cuff 106a form a curved surface. The curved surface has a curvature similar to (e.g., matching) the outer surface 74 of the drum 52, so that when the first cuff 106a is received in the opening 82a, the flange 150 extends beyond the opening 82. The flange 150 extends along the outer surface 74 of the drum 52. In the illustrated embodiment, there is a void gap between the flange 150 and the outer surface 74 of the drum 52. In some embodiments, the flange 150 is flush with the outer surface 74 of the drum 52.

[0053] In some embodiments (not shown), the flange 150 includes a set of contact points (e.g., bosses, knobs, or protrusions) such that when the first cuff 106a is inserted into the opening 82a, the flange 150 contacts the outer surface 74 of the drum 52 only at the contact points. The flange 150 may include three or more contact points spaced apart along the flange 150. The contact points may be integrally formed with the first cuff 106a.

[0054] The hammer cavity 126 is configured to at least partially receive one of the hammers 58. The hammer cavity 126 has a generally rectangular cross-section (e.g., Fig.13 58). In the illustrated embodiment, the hammer cavity 126 has rounded edges. The hammer cavity 126 is sized to fit one of the hammers in the hammer 58. The hammer cavity 126 is sized to be only slightly larger than one of the hammers in the hammer 58. The hammer cavity 126 can be centered on the first band 106a so that the center of the hammer cavity 126 is aligned with the center of the first band 106a. The hammer cavity 126 can be formed during the forging process of the first band 106a, or can be formed by machining (e.g., cutting or drilling) after the first band 106a is forged. In some embodiments, the hammer cavity 126 can be off-center on the first band 106a.

[0055] The hammer cavity 126 may include an inner contour 142 ( Fig.19 ). The inner profile 142 is configured to receive a sleeve (discussed in detail below). The inner profile 142 is positioned at the distal end of the inner portion 118 (e.g., the end of the first cuff 106a opposite the flange 150). The inner profile 142 partially extends from the distal end of the first cuff 106a toward the flange 150. The inner profile 142 may extend only one-fifth of the length of the inner portion 118. In some embodiments, the inner profile 142 may extend only one-third of the length of the inner portion 118. In some embodiments, the inner profile 142 may extend the length of the inner portion 118. In some embodiments, the inner profile 142 may extend the entire length of the first cuff 106a.

[0056] The first cuff 106a may also include a wedging side 110 (e.g., a first side) and a support side 114 (e.g., a second side). The hammer cavity 126 is located between the wedging side 110 and the support side 114. In the illustrated embodiment, when the first cuff 106a is positioned in the opening 82a, the wedging side 110 is forward relative to the rotational direction 70, and the support side 114 is rearward relative to the rotational direction 70. In some embodiments, the support side 114 may be forward relative to the rotational direction 70. In some embodiments, the first cuff 106a may include two wedging sides 110 (e.g., a front wedging side and a rear wedging side) and no support side. In some embodiments, the first cuff 106a may include two support sides 114 (e.g., a front support side and a rear support side) and no wedging side.

[0057] The wedging side 110 includes a wedging cavity 130 that extends the length of the first cuff 106a. The wedging cavity 130 and the hammer cavity 126 may open to each other directly or indirectly. The wedging cavity 130 and the hammer cavity 126 may be directly adjacent and directly open to each other. In the illustrated embodiment, the wedging cavity 130 is continuous (e.g., fluidly connected) with the hammer cavity 126. The wedging cavity 130 may be formed during the forging process of the first cuff 106a, or may be formed by machining (e.g., cutting or drilling) after forging the first cuff 106a. In some embodiments, the wedging cavity 130 may only partially extend the length of the first cuff 106a.

[0058] refer to Fig.24 and Fig. 27 , the wedging assembly 204 is disposed in the wedging cavity 130. The wedging assembly 204 removably secures the hammer 58 to the first hoop 106a. The operation of the wedging assembly 204 applies a force perpendicular to the length of the hammer 58 to the hammer 58 so as to clamp or wedge the hammer 58 to the first hoop 106a. The wedging assembly 204 may include a first wedge 208, a second wedge 212, and a fastener 214 (e.g., a bolt). The fastener 214 extends through the first wedge 208 and the second wedge 212. The fastener 214 does not extend through the hammer 58 or the reducer 62.

[0059] The first wedge 208 includes a groove 218, an angled contact surface 221, and a wedge surface 223. The groove is configured to receive a portion of the fastener 214. The wedge surface 223 is opposite the angled contact surface 221. The wedge surface 223 is adjacent to the collar 106.

[0060] The second wedge 212 has an L-shape. The second wedge 212 includes a base 228, an inclined contact surface 232, and a wedge surface 234. The base 228 includes a groove 225 that receives a portion of the fastener 214. The base 228 is positioned below the first wedge 208. The inclined contact surface 232 is positioned between the inclined contact surface 221 of the first wedge 208 and the hammer 58. The inclined contact surface 232 of the second wedge 212 is configured to engage with the inclined contact surface 232 of the first wedge 208. The wedge surface 234 is opposite to the inclined contact surface 232. The wedge surface 234 is adjacent to the hammer 58 and applies a force to the hammer 58. The force is perpendicular to the length of the hammer 58.

[0061] The fastener 214 is received in both the first wedge 208 and the second wedge 212 and is threadedly received by the nut 235. In some configurations, the nut 235 is T-shaped. The nut 235 is positioned below both the first wedge 208 and the second wedge 212. The wedging cavity 130 may have a protrusion 236 that separates the wedges 208, 212 from the nut 235 and limits the axial movement of the nut 235. In other embodiments, the nut 235 may be a hexagonal nut or a square nut.

[0062] As the fastener 214 is tightened into the nut 235, the fastener 214 forces the first wedge 208 to engage with the second wedge 212. More specifically, tightening the fastener 214 pushes the first wedge 208 downward (e.g., toward the inner cavity 78) and forces the inclined contact surface 232 of the first wedge 208 to engage with the inclined contact surface 232 of the second wedge 212. The first wedge 208 pushes the wedge surface 234 of the second wedge 212 laterally against the hammer 58, so that the hammer is fixed (e.g., wedged or clamped) into the first hoop 106a and cannot be removed. When the fastener 214 is loosened, the fastener 214 allows the first wedge 208 to disengage from the second wedge 212. Loosening the first wedge 208 allows the first wedge 208 to apply less force to the second wedge 212. The hammer 58 is no longer fixed, so that the hammer 58 can be removed from the first hoop 106a.

[0063] The wedging side 110 may also include an extension 134. The extension 134 extends beyond the support side 114. The extension 134 includes a cover 238 and a divider 242 that extend the length of the wedging cavity 130. The cover 238 is configured to cover the wedging cavity 130 and prevent the nut 235 from falling into the inner cavity 78 of the drum 52. The divider 242 allows the fastener 214 and the nut 235 to be positioned in the wedging cavity 130 and allows additional space for the fastener 214 to move downward.

[0064] The divider 242 is welded to the distal end of the wedging side 110 by weld 246. The cover 238 is welded to the divider 242 by weld 250. In some embodiments, the divider 242 and the cover 238 are a unitary piece. In some embodiments, the divider 242 and the cover 238 are included in a single-piece forging of the first hoop 106a.

[0065] The support side 114 provides strength to the first cuff 106a. The support side 114 is a completely solid structure and does not have any openings. The support side 114 does not have any detachable parts or components.

[0066] refer to Figures 20 to 27 , the subtractive rotor system 50 may include a sleeve 174 coupled to the first hoop 106a and the second hoop 106b. More specifically, the sleeve 174 may be press-fitted into the inner profile 142 of the first hoop 106a and the second hoop 106b. The sleeve 174 is a rectangular extension configured to receive a hammer. The sleeve 174 has a constant rectangular cross-section. The sleeve 174 extends through the inner cavity 78 of the drum and extends at least partially between the first opening 82a and the second opening 82b. More specifically, the sleeve 174 extends between the first hoop 106a and the second hoop 106b. The sleeve 174 prevents objects (e.g., hammers, dust, shaved materials, etc.) from accidentally falling into the inner cavity 78 of the drum 52, which may not be accessible or close to the inner cavity 78 once assembled in the subtractive machine.

[0067] In addition, the sleeve 174 can be used during assembly of the rotor weldment 56 to form an air gap between the hoops 106a, 106b and the outer surface 74 of the drum 58. More specifically, the length of the sleeve 174 can be selected to form the gap and control the size of the gap between the hoops 106a, 106b and the outer surface 74. The first end of the sleeve 174 is received in the inner profile 142 of the first hoop 106a, and the second end of the sleeve 174 is received in the inner profile 142 of the second hoop 106b. The length of the sleeve 174 separates the first hoop 106a and the second hoop 106b from each other. In order to set an increased distance between the first hoop 106a and the second hoop 106b, the length of the sleeve 174 can be increased. In order to set a reduced distance between the first hoop 106a and the second hoop 106b, the length of the sleeve 174 can be reduced. The length of sleeve 174 is selected to achieve a desired gap between first cuff 106a and outer surface 72 and a desired gap between second cuff 106b and outer surface 72. The desired gaps allow for a more controlled and consistent weld (discussed in detail below).

[0068] refer to Figure 6 , Fig.10 , Fig.11 and Fig. 20The rotor weldment 56 may include a plurality of wear plates 90 (e.g., a coating or shell) extending along the outer surface 74 of the drum 52. The plurality of wear plates 90 are fixed to the outer surface 74 of the drum 52. More specifically, the plurality of wear plates 90 are welded to the outer surface 74 of the drum 52. The plurality of wear plates 90 may be formed of a harder material than the outer surface 74. The material of the wear plates 90 may be 500 wear-resistant steel. Alternatively, the wear plates 90 may be made of another suitable wear-resistant steel. Compared to a single roller 52, the plurality of wear plates 90 improves the strength and wear resistance of the rotor weldment 56.

[0069] In the illustrated embodiment, the plurality of wear plates 90 include a first wear plate 90a, a second wear plate 90b, a third wear plate 90c, and a fourth wear plate 90d. The first wear plate 90a is circumferentially adjacent to the second wear plate 90c, and the third wear plate 90c is circumferentially adjacent to the fourth wear plate 90d. The first wear plate 90a is axially adjacent to the third wear plate 90c, and the second wear plate 90d is axially adjacent to the fourth wear plate 90d. In the illustrated embodiment, the wear plates 90a-90d are all similar, so only the first wear plate 90a will be described in detail.

[0070] The first wear plate 90a includes an inner surface 94, an outer surface 98 and at least one curved edge 102. When the first wear plate 90a is positioned on the drum 52, the inner surface 94 of the first wear plate 90a abuts against the outer surface 74 of the drum 52 and is flush with the outer surface 74. The first wear plate 90a defines a curved inner surface 94. In the illustrated embodiment, the inner surface 94 has a semicircular shape. The second wear plate 90b is positioned adjacent to the first wear plate 90a along the circumference to cover the periphery of the drum 52. Circumferentially adjacent wear plates (e.g., the first wear plate 90a and the second wear plate 90b) can abut against each other, or there can be a gap defined between the wear plates 90a, 90b. In other embodiments, the wear plates can be smaller, so that three or more wear plates can be used to cover the periphery of the drum 52. Similar to the opening 82, the first wear plate 90a and the second wear plate 90b are angularly offset from the third wear plate 90c and the fourth wear plate 90d, such as Fig. 20 In the illustrated embodiment, the groups of wear plates are offset by 60 degrees. In some embodiments, the angular offset may be greater or less.

[0071] The first wear plate 90a has two curved edges 102. When the first wear plate 90a is positioned on the drum 52, the curved edges 102 are positioned adjacent to corresponding portions of the opening 82 of the drum 52. In other words, the edges 102 follow the contour of a portion of the opening 82. In the illustrated embodiment, the edges 102 have a semi-oval shape so that the two wear plates form an oval opening that follows the contour of one of the openings 82 or follows the contour of one of the hoops 106. For example, referring to Figure 6 , an oval opening is formed between the first wear plate 90a having edge 102a and the fourth wear plate 90d having edge 102d. In some embodiments, the first wear plate 90a has an oval opening so that only one wear plate (e.g., the first wear plate 90a) is required to form an opening corresponding to the opening 82. In some embodiments, the wear plate 90 may have a welding lug extending from the wear plate 90 and allowing welding to be performed on the lug.

[0072] The wear plate 90 can be positioned adjacent to the collar 106 while allowing clearance for welding between the wear plate 90 and the collar 106. For example, in the illustrated embodiment, the first wear plate 90a is positioned adjacent to the first collar 106a. More specifically, the edge 102 of the first wear plate 90a is adjacent to the outer portion 122 of the first collar 106a. The edge 102 can be offset from the outer portion 122 such that a weld gap 152 ( Fig. 27 ). The outer surface 74 of the drum 52 is exposed at the weld gap 152. The weld gap 152 may extend along the entire perimeter of the outer portion 122, or the weld gap 152 may extend only partially along the perimeter of the outer portion 122. In some embodiments, the first wear plate 90a is immediately adjacent to the first hoop 106a, and no weld gap is defined between the first wear plate 90a and the first hoop 106a.

[0073] refer to Fig. 27, at the weld gap 152, the first wear plate 90a, the first hoop 106a, and the outer surface 74 of the drum 52 can be welded together to form the rotor weldment 56. The welding can be completed by at least one weld spanning the weld gap 152. In the illustrated embodiment, the weld gap 152 is filled with a plurality of welds 154. The plurality of welds 154 may include a first weld bead 158, a second weld bead 162, and a third weld bead 166. The first weld bead 158 is applied between the outer portion 122 of the first hoop 106a and the outer surface 74 to secure the first hoop 106a to the outer surface 74. The second weld bead 162 is applied between the first wear plate 90a and the outer surface 74 to secure the first wear plate 90 to the outer surface 74. The third weld bead 166 is applied between the first weld bead 158 and the second weld bead 162 to secure the first hoop 106a, the first wear plate 90a, and the outer surface 74 together. The first weld bead 158 and the second weld bead 162 can each be formed by a plurality of weld passes (weld pass) (e.g., welding layer). For example, the first weld bead 158 and the second weld bead 162 can each be formed by three weld passes. The weld pass can be a continuous weld extending along the entire outer perimeter of the first hoop 106a and the edge 102 of the first wear plate 90a. In some embodiments, the weld pass can be a discontinuous weld extending along the outer perimeter of the first hoop 106a and the edge 102 of the first wear plate 90a. In some embodiments, weld beads 158, 162, 166 can be applied in different orders. In some embodiments, a plurality of welds 154 can include more welds. In some embodiments, the wear plate 90 can be directly welded to the hoop 106 with minimal or no welds, thereby connecting the wear plate 90 to the outer surface 74 of the drum 52.

[0074] Fig.28 A rotor weldment 56' is shown according to another embodiment. The rotor weldment 56' is similar to the rotor weldment 56, but the rotor weldment 56' includes a different weld pattern. The flange of the first hoop 106a, the outer surface 74 of the drum 52, and the wear plate 90' ​​of the rotor weldment 56' are fixed or fused together by a single weld 154'. The single weld 154' is a single weld bead formed in a single weld pass that fills the entire weld gap 152. The single weld 154' can be achieved by applying a single weld bead on the outer surface 74 of the drum 52, the flange of the first hoop 106a, and the wear plate 90 using submerged arc welding.

[0075] Fig. 27 and Fig.28The welds 154, 154' are shown extending along the surface of the drum 52, 52'; the first hoop 106, 106'; and the wear plate 90, 90'. However, those skilled in the art of welding will recognize that the welds 154, 154' penetrate to and fuse with the base material of the drum 52, 52'; the first hoop 106, 106' and the wear plate 90, 90'.

[0076] refer to Fig. 20 and Fig.21 The drum 52, the collar 106, the wear plate 90 and the weld 154 form the rotor weldment 56. The weld 154 fuses the drum 52, the collar 106 and the wear plate 90 together to form the rotor weldment 56. The rotor weldment 56 is permanently coupled together. The hammer 58 is removably coupled to the rotor weldment 56.

[0077] The cuff 106 and welds 154, 154' increase the strength of the drum 52. More specifically, the cuff 106 and welds 154, 154' reduce the amount of stress along the outer surface 74 of the drum 52 at the perimeter of the opening 82. As the reducer 62 repeatedly strikes the material, the cuff 106 prevents the trailing edge of the opening 82 (e.g., the edge adjacent to the support side 114 of the cuff 106) from being overstressed. The rotor weldment 56 forms a load path that transfers some or most of the loads (e.g., stresses) experienced by the reducer 62 and hammer 58 during reduction through the cuff 106 (via the flange 150) to the drum 52 and / or the wear plate 90. The load path distributes the load to the rotor weldment 56 rather than concentrating the load at the perimeter of the opening 82.

[0078] refer to Fig.24 The hammer 58 includes a first end 182 and a second end 186 opposite the first end 182. In the illustrated embodiment, the hammer 58 has a generally rectangular shape. More specifically, the ends 182, 186 may be wider than the center portion of the hammer 58.

[0079] During assembly, the hammer 58 is positioned in the sleeve 174, which extends into the inner cavity 78 of the drum 52, and the hammer 58 is removably coupled to the first and second cuffs 106a, 106b. More specifically, the first end 182 of the hammer 58 is received in the first cuff 106a, and the hammer 58 extends longitudinally across the rotation axis 54 to the second cuff 106b, so that the second end 186 of the hammer 58 is received in the second cuff 106b. In the configuration where the hammer has a reducer on the first end 182 and / or the second end 186, a portion of the hammer 58 can be exposed (e.g., located outside the drum 52 and the cuffs 106a, 106b). The (one or more) exposed portions can have a cutting shape or can be used as a support or mounting member for the reducer 62. In some embodiments, the hammer 58 has a smaller length and does not extend across the rotation axis 54, so that the first hammer is received in the first cuff 106a, and the second hammer is received in the second cuff 106b.

[0080] The first end 182 of the hammer 58 may be a cutting end configured to be removably coupled to the reducer 62. The reducer 62 may be removably coupled to the first end 182 by fasteners 194 (e.g., bolts or screws). In the illustrated embodiment, the reducer 62 is coupled to the first end 182 by two fasteners 194. The fasteners 194 are inserted through the reducer 62 and into the hammer 58 in a direction perpendicular to the longitudinal direction of the hammer 58. The reducer 62 includes a sharp tool face 66. The tool face 66 is located above the wedging side 110 of the first hoop 106a so that the tool face 66 faces forward relative to the direction of rotation 70. The reducer 62 may be replaced or removed from the hammer 58 by loosening the fasteners 194. The reducer 62 may be removed without removing the hammer 58 from the hoop 106 and the rotor weldment 56.

[0081] refer to Fig.23 , Fig.25 and Fig.26 , the second end 186 of the hammer 58 may be the blank end that is not coupled to the reducer 62. The second end 186 is removably coupled to a cover 198 that covers the second end 186. The cover 198 is coupled to the second end 186 by fasteners 202 (e.g., bolts or screws). In the illustrated embodiment, the cover 198 is coupled to the second end 186 by two fasteners 202. The fasteners 202 are inserted through the cover 198 and into the hammer 58 in a direction parallel to the hammer 58.

[0082] In some embodiments, both the first end 182 and the second end 186 may be cut ends. In some embodiments, both the first end 182 and the second end 186 may be blank ends.

[0083] Additionally, a detailed description of a hammer that may be similar to hammer 58 is provided in US Pat. No. 11,338,298 to Vermeer Mfg. Co., the entire contents of which are incorporated herein by reference.

[0084] The subtractive rotor system 50 is assembled by first providing the drum 52. The drum 52 includes at least a first opening 82a and a second opening 82b disposed in the outer surface 74 of the drum 52.

[0085] Then, the first cuff 106a is inserted (e.g., assembled, positioned, or located) into the first opening 82a from the outside of the drum 52 until the inner portion 118 extends into the drum 52 and the outer portion 122 (more specifically, the flange 150 of the outer portion 122) extends beyond the first opening 82a and along the outer surface 74 of the drum 52. The sleeve 174 is inserted into the inner profile 142 of the first cuff 106a through the second opening 82b so that the sleeve 174 is press-fit into the first cuff 106a and extends between the first opening 82a and the second opening 82b. In some embodiments, the sleeve 174 can be press-fit into the first cuff 106a before the first cuff 106a is inserted into the first opening 82a so that the sleeve 174 is inserted into the drum 52 when the first cuff 106a is inserted into the drum 52.

[0086] Next, the second cuff 106b is inserted (e.g., seated) into the second opening 82b until the inner portion 118 extends into the drum 52 and the outer portion 122 (more specifically, the flange 150 of the outer portion 122) abuts the outer surface 74 of the drum 52. The second cuff 106b is aligned with the first cuff 106a and the sleeve 174 such that the second cuff 106b is coupled to the sleeve 174. More specifically, when the second cuff 106b is inserted into the second opening 82b, the sleeve 174 is aligned with the inner profile 142 of the second cuff 106b such that the sleeve 174 can be press-fit into the inner profile 142 when the second cuff 106b is fully inserted into the opening 82b. The second cuff 106b is inserted into the second opening 82b such that the wedging side 110 of the second cuff 106b is directionally aligned with the wedging side 110 of the first cuff 106a with reference to the intended rotational direction 70 .

[0087] Once the first and second ferrules 106a, 106b are positioned in their respective openings 82a, 82b, the wear plates 90a-90d are positioned on the outer surface 74 of the drum 52. The wear plates 90a-90d are positioned such that the inner surfaces 94 of the wear plates 90a-90d abut the outer surface 74 of the drum 52 and such that the edges 102 are adjacent to the outer portions 122 of the ferrules 106a, 106b (more specifically, the flanges 150 of the outer portions 122). The wear plates 90a-90b are also positioned such that the wear plates 90a-90b are offset from the outer portions 122 of the ferrules 106a, 106b, thereby forming a weld gap 152 between the ferrules 106a, 106b and the wear plates 90a-90d.

[0088] The first and second bands 106a, 106b, and wear plates 90a-90d are then secured to the outer surface 74 of the drum 52 to form the rotor weldment 56. More specifically, the first and second bands 106a, 106b, and wear plates 90a-90d are welded to the outer surface 74 of the drum 52. Even more specifically, the flange 150 of the first band 106a, the flange 150 of the second band 106b, and the outer surfaces 98 of the wear plates 90a-90d are welded to the outer surface 74 of the drum 52. Welding the first and second bands 106a, 106b, and wear plates 90a-90d may include depositing a plurality of weld beads in the weld gap 152. More specifically, the flange 150 of the first hoop 106a is welded to the outer surface 74 of the drum 52 by depositing a first weld bead at the weld gap 152 between the first hoop 106a and the outer surface 74 to form a first weld bead 158. Then, the outer surface 98 of the wear plate 90a is welded to the outer surface 74 of the drum 52 by depositing a second weld bead at the weld gap 152 between the wear plate 90a and the outer surface 74 to form a second weld bead 162. Finally, the first hoop 106a, the wear plate 90a, and the outer surface 74 are welded together by depositing a third weld bead at the weld gap 152 to form a third weld bead 166 between the first weld bead 158 and the second weld bead 162. A similar welding process can be repeated on the other side of the drum 52 to secure the second hoop 106b and the second wear plate 90b to the outer surface 74 of the drum 52. As described above, different welding configurations can be used in forming the rotor weldment 56.

[0089] Once the rotor weldment 56 is formed, the hammer 58 is inserted into the drum 52 via the first band 106a. The hammer 58 is inserted through the first band 106a and into the sleeve 174. The hammer 58 is inserted until the second end 186 of the hammer 58 is received in the second band 106b and a portion of the hammer 58 remains exposed.

[0090] Then, the hammer 58 is fixed to the first hoop 106a and the second hoop 106b. The hammer 58 is fixed to the first hoop 106a by tightening the fastener 214 to push the wedge surface 234 of the first wedge 208 and the second wedge 212 against the wedging side 110 of the hammer 58. As the fastener 214 is tightened, the fastener 214 moves downward (e.g., toward the inner cavity 78) and pushes the first wedge 208 downward. The inclined contact surface 221 of the first wedge 208 is wedged against the inclined contact surface 232 of the second wedge 212, thereby fixing and clamping the hammer 58 to the first hoop 106a. A similar wedging process can be repeated on the other side of the drum 52 to fix the hammer 58 to the second hoop 106b and the drum 52.

[0091] Once the hammer 58 is secured to the first and second ferrules 106a, 106b, the reducer 62 is coupled to the first end 182 and the cap 198 is coupled to the second end 186. The reducer 62 is aligned with the hammer 58 so that the tool face 66 of the reducer 62 faces the direction of rotation 70. The reducer 62 is coupled to the hammer 58 by inserting the fastener 194 through the reducer 62 and into the hammer 58, and tightening the fastener 194 to secure the reducer 62. The fastener 194 is inserted in a perpendicular direction relative to the hammer 58. On the second end 186, the cap 198 is coupled to the hammer 58 by inserting the fastener 202 through the cap 198 and into the hammer 58, and tightening the fastener 202 to secure the cap 198. The fastener 202 is inserted in a parallel direction relative to the hammer 58.

[0092] Once the reducer 62 and cover 198 are secured to the hammer 58, the first end cap 53 and the second end cap 55 may be secured to the ends of the rotor weldment 56. Once the end caps 53, 55 are secured to the rotor weldment 56, the subtractive rotor system 50 may be placed into a subtractive machine, such as the rotary subtractive machine 20, so that the drum rotor weldment 56 and the subtractive rotor system 50 may be driven to rotate about the rotation axis 54 and the central axis 26. In some embodiments, after the rotor weldment 56 is mounted to the subtractive machine, the hammer 58 is secured to the rotor weldment 56 along with the reducer 62 and cover 198.

[0093] If one of the reducers 62 breaks or becomes worn, one of the reducers 62 can be easily replaced by loosening the fasteners 194 to decouple the reducer 62 from the hammer 58. Once the old reducer 62 is decoupled, a new reducer 62 can be coupled to the hammer 58 using the fasteners 194. During replacement of the reducers 62, the hammer 58 and the collar 106 remain fixed in the drum 52.

[0094] If the hammer 58 becomes worn, broken, or requires inspection, the hammer 58 can be easily replaced by first removing any reducers 62 or covers 198 coupled to the hammer 58, and then loosening the fasteners 214 in the first and second hoops 106a, 106b. Loosening the fasteners 214 removes the hammer 58 so that it can easily slide out of the hoops 106a, 106b and the drum 52.

[0095] Although the method of assembling the subtractive rotor system 50 is described in sequential steps, it should be understood that some of the steps may be completed in a different order, some of the steps may be completed simultaneously, and some of the steps may be omitted.

[0096] Furthermore, the articles “a” and “an” should not be construed as meaning “one” or “only one” unless the context in which they are used clearly indicates otherwise. Instead, these articles should be construed as meaning “at least one” or “one or more”.

[0097] While certain embodiments, examples, features, and aspects have been described and illustrated, changes and modifications exist within the scope and spirit of the subject matter explained and illustrated.

Claims

1. A method of assembling a rotary subtractive tool, comprising: providing a drum having an outer surface extending about an axis of rotation of the drum; Assembling a cuff from outside the drum into a first opening in the outer surface of the drum until a portion of the cuff extends into the drum and a flange of the cuff extends beyond the first opening and along the outer surface of the drum; welding the flange of the hoop to the outer surface of the drum; inserting a hammer through the collar such that a portion of the hammer remains exposed; and The hammer is secured to the collar.

2. The method according to claim 1, wherein: Welding the flange of the collar and the outer surface of the drum together includes depositing a plurality of weld beads.

3. The method of claim 1 further comprising seating a second cuff in a second opening in the outer surface of the drum until a portion of the second cuff extends into the drum and a flange of the second cuff extends beyond the first opening and along the outer surface of the drum, wherein the second opening is opposite the first opening.

4. The method of claim 3, further comprising press fitting a sleeve into the cuff, the sleeve extending between the cuff and the second cuff.

5. The method according to claim 1, wherein: The hammer is secured to the ferrule by tightening a fastener to one side of the ferrule to wedge the hammer into the ferrule.

6. The method of claim 1 further comprising securing a wear plate to the outer surface of the drum.

7. The method according to claim 6, wherein: The wear plate is fixed to the outer surface of the drum by welding.

8. The method according to claim 7, wherein: Welding the flange of the collar and the outer surface of the drum together includes depositing a first weld bead, and welding the wear plate and the outer surface of the drum together includes depositing a second weld bead, the method further comprising depositing at least one additional weld bead between the first and second weld beads.

9. The method according to claim 7, wherein: Welding the flange of the hoop and the outer surface of the drum together and welding the wear plate and the outer surface of the drum together includes applying a single weld bead between the flange of the hoop, the outer surface of the drum, and the wear plate.

10. A rotary subtractive tool comprising: a drum having an outer surface extending about a rotational axis of the drum, the drum having a first opening defined in the outer surface of the drum; a cuff received in the first opening, wherein a first portion of the cuff extends into the drum and a flange of the cuff extends beyond the first opening and along the outer surface of the drum; and a hammer extending through the collar and into the drum, the hammer having an exposed portion, Wherein, the flange of the hoop is welded to the outer surface of the roller.

11. The rotary subtractive tool of claim 10 further comprising a second band coupled to a second opening in the outer surface of the drum, the second opening being opposite the first opening, a first portion of the second band extending into the drum, and a flange of the second band extending outside the drum.

12. The subtractive rotary tool of claim 10, further comprising a wear plate secured to the outer surface of the drum.

13. The rotary subtractive tool of claim 12, wherein: The hoop, the wear plate and the outer surface of the drum are welded together.

14. The rotary subtractive tool of claim 10, wherein: The outer perimeter of the cuff forms a curved surface.

15. The rotary subtractive tool of claim 10, wherein: The flange extends beyond the entire perimeter of the first opening.

16. The rotary subtractive tool of claim 10, further comprising a sleeve extending at least partially between the first opening and a second opening in the outer surface, the second opening being opposite the first opening, and the hammer being at least partially positioned within the sleeve.

17. The rotary subtractive tool of claim 10, wherein: The collar includes a wedging side and a supporting side, wherein the wedging side includes a fastener and a wedging assembly that secures the hammer to the collar when the fastener is secured.

18. The rotary subtractive tool of claim 17, wherein: The support side is a completely solid structure without any openings.

19. The rotary subtractive tool of claim 10, wherein: The hoop is a one-piece forging.

20. The rotary subtractive tool of claim 10, wherein: The hammer extends transverse to the rotation axis.

Images