Rotatable Cutting Chain With Annular Support for Deep Hard-Material Cuts
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Solution Overview
Problem
Existing work tools for cutting hard materials like concrete and stone face significant mechanical wear and limited cutting depth due to energy storage and handling issues with cut-off discs and rapid wire wear in abrasive operations.
Innovation Solution
A rotatable cutting chain work tool with an annular member supported by rollers and a separate support wheel, distributing mechanical stress evenly across chain links, allowing for deep cuts without significant energy storage, and featuring a replaceable annular member for adjustable torque and speed ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cut-off disc is used for cutting hard materials, then the cutting capability is improved, but the weight and stored energy increase making handling cumbersome
Solution Approach 1:
The cutting tool is segmented into a chain with discrete cutting elements rather than a solid disc. The chain consists of individual links with carbide inserts that can be replaced independently, distributing the cutting function across multiple small elements rather than one large mass, thereby reducing overall weight while maintaining cutting capability.
Solution Approach 2:
The chain uses replaceable carbide inserts on individual links that can be quickly swapped when worn, rather than replacing an entire heavy disc. This allows the use of lighter materials and reduces the weight of the moving cutting component while maintaining reliable cutting performance through periodic replacement of wear elements.
2Reliability
If a cut-off disc is used for cutting hard materials, then the cutting capability is improved, but the achievable cutting depth is limited to about half the diameter of the disc
Solution Approach 1:
The cutting system uses a flexible chain that can be dynamically positioned and guided around the workpiece rather than a rigid disc with fixed geometry. The chain can accommodate varying cut depths and be routed through guides to achieve cutting depths exceeding the diameter limitations of disc-based systems.
3Length of stationary object
If a wire is used for abrasive operation to cut hard materials, then deep cuts can be made, but the wire is likely to wear out fast due to the relatively small number of abrasive wire beads
Solution Approach 1:
Instead of distributing abrasive elements uniformly along a wire, the invention concentrates high-hardness carbide inserts at specific cutting points on chain links. This local concentration of cutting quality at the chain teeth provides enhanced durability and cutting efficiency compared to distributed abrasive beads on a wire, extending the duration of action.
4Length of stationary object
If a chain saw is adapted for abrasive operation, then it can cut deeper compared to cut-off discs, but the cutting chain is subject to mechanical stress causing it to wear out fast
Solution Approach 1:
The chain links are constructed as composite structures combining tough base metal for mechanical strength with hard carbide inserts for abrasion resistance. This composite approach allows the chain to withstand the mechanical stresses of deep cutting while the carbide inserts resist wear, significantly extending chain life compared to homogeneous material constructions.
Solution Approach 2:
The design allows individual worn carbide inserts to be discarded and replaced on the chain links without replacing the entire chain. This selective replacement strategy extends the overall life of the chain assembly by recovering and reusing the durable chain link structure while replacing only the consumable cutting elements.
Data Source
AI summary
A work tool (100) comprising: a cutting chain (110), a drive mechanism for driving the cutting chain (110), an annular member (120) arranged rotatably supported by one or more support rollers (130,140,150), wherein the annular member comprises a rim (230) adapted to support the cutting chain (110) during cutting, and a support wheel (160) arranged distanced from the annular member (120), wherein the cutting chain (110) is arranged supported on a rim segment (102) of the annular member (110) forming part of a cutting area of the tool (100) and supported on a rim segment (103) of the support wheel (160) in a direction away from the cutting area of the tool (100). An annular member and a method of producing an annular member are also disclosed.