Abrasive Tool Splice Gap Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The splicing of production tool ends in abrasive article manufacturing often results in gaps in the pattern of shaped abrasive particles due to the interruption of cavities, leading to breaks in the final product.
Innovation Solution
A method and system are developed to fill or prevent gaps in abrasive articles by using a production tool with a spliced region, where excess abrasive particles are supplied and filling assist members help orient and transfer particles into cavities, and a control and visual system detects gaps to automatically fill them with additional particles, ensuring a continuous pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the production tool ends are spliced together to form an endless belt, then the production tool can be reused continuously, but gaps in the abrasive particle pattern are created at the spliced region
Solution Approach 1:
The production tool is divided into multiple cavities, with a specific cavity designated as a splice accommodation cavity that can open and close to accommodate the spliced region. This segmentation allows the tool to maintain its cavity structure while providing a controlled opening for the splice, preventing gaps in the abrasive particle pattern.
Solution Approach 2:
The splice accommodation cavity is pre-configured to open before the spliced region reaches it and close after the splice passes through. This preliminary action ensures that the cavity structure is maintained at all times except when necessary for the splice, preventing gaps in the abrasive particle pattern while allowing continuous tool operation.
2Productivity
If the production tool is made as an endless belt for continuous production, then productivity increases, but the splicing process interrupts the cavity structure causing pattern breaks
Solution Approach 1:
The production tool cavities are segmented such that one cavity is dedicated as a splice accommodation cavity that can independently open and close. This allows the rest of the tool to maintain continuous cavity structure for uninterrupted abrasive particle transfer, while the splice cavity handles the splicing operation without affecting overall productivity or pattern integrity.
Solution Approach 2:
The splice accommodation cavity acts as an intermediary that temporarily accommodates the spliced region during the splicing process. By providing this intermediate structure, the tool maintains continuous operation capability while ensuring the splice does not create gaps in the abrasive particle pattern, thus preserving both productivity and reliability.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A system and method for producing an abrasive article includes a production tool configured to provide shaped abrasive particles to a resin coated backing. A first end and a second end of the production tool are spliced together to form a spliced area. The production tool includes a dispensing surface that includes a plurality of cavities formed between the first end and the second end and configured to receive and hold the shaped abrasive particles. The resin coated backing is configured to receive the shaped abrasive particles from the dispensing surface of the production tool and configured to receive further shaped abrasive particles to fill gaps in the shaped abrasive particles caused by an absence of the plurality of cavities in the spliced area.