Overlapping Abrasive Chain Elements to Reduce Gap Kick-Back
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Abrasive cutting tools for hard materials like concrete, steel, and stone face issues of short tool life, overcutting, and operator safety due to kick-back, primarily caused by gaps between elements on flexible drive carriers that lead to mechanical stress and snagging.
Innovation Solution
The introduction of protruding members that overlap adjacent elements on flexible drive carriers, such as chains or belts, to cover gaps formed when bent, reducing mechanical stress, preventing snagging, and enhancing operator safety by maintaining a continuous abrasive surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If gaps are left between adjacent elements on flexible drive carriers, then the elements can move independently to accommodate bending, but the elements impact the material to be cut causing mechanical stress, snagging, and kick-back
Solution Approach 1:
A non-abrasive protruding member is introduced as an intermediary element between adjacent abrasive elements. This protruding member fills the gap that forms when the flexible drive carrier bends, preventing the abrasive elements from impacting the material. The protruding member acts as a buffer that eliminates harmful mechanical stress and kick-back while allowing the drive carrier to maintain its flexibility
Solution Approach 2:
The drive carrier is segmented into multiple discrete elements (abrasive elements and non-abrasive protruding members) arranged in an alternating pattern. This segmentation allows each element to move independently, accommodating the bending of the flexible drive carrier while the protruding members specifically address the gap formation issue
2Length of moving object
If diamond cutting chains are used to achieve deep cutting, then cutting depth is improved, but tool life is short requiring frequent replacement
Solution Approach 1:
The non-abrasive protruding members serve as protective intermediaries that prevent the abrasive elements from excessive mechanical impact with the material. By absorbing and distributing the mechanical stress, these protruding members reduce wear on the abrasive elements, thereby extending tool life while maintaining the ability to cut at depth
Solution Approach 2:
The protruding members are positioned beforehand to anticipate and cushion the mechanical impact that would otherwise occur when the flexible drive carrier bends during operation. This prior cushioning prevents sudden shocks to the abrasive elements, reducing wear and extending tool life
3Adaptability or versatility
If gaps exist between elements when the drive carrier is bent, then flexibility is maintained, but the elements snag on the material causing operator safety issues
Solution Approach 1:
The non-abrasive protruding members act as safety intermediaries that fill the gaps formed during bending. By preventing the abrasive elements from exposing sharp edges or creating uneven surfaces, these protruding members eliminate snagging hazards and improve operator safety while preserving the flexibility needed for various cutting applications
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 prolongs tool life, reduces the risk of kick-back, and improves cutting efficiency by minimizing mechanical stress and vibration, while maintaining optimal contact pressure between the abrasive material and the workpiece.
Implementation Method 1
the gap G that forms between adjacent elements as the flexible drive carrier is bent is at least partly covered. This prevents the elements to impact the material to be cut, which results in several advantages; For instance, tool life is prolonged, operator comfort is increased, and cutting efficiency may also be increased
Implementation Method 2
The element can according to some aspects be a cutting element configured to include or hold an abrasive compound or material, and to perform an abrasive operation
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
An element for serial configuration with an adjacent element in an abrasive tool, wherein the element is arranged to be mounted on a flexible drive carrier having a drive direction D. The element comprising at least one protruding member extending in a direction parallel to the drive direction D. The at least one protruding member being configured to overlap with the adjacent element at least when the flexible drive carrier has a straight configuration, and to reduce a width of a gap G formed between the element and the adjacent element when the flexible drive carrier is configured bent in an arcuate form.