Ceramic Log Cutting and Grinding with Dual-Blade Saw
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Solution Overview
Problem
Existing methods for cutting and grinding ceramic logs are inefficient, requiring multiple process steps, water-cooled equipment, and resulting in imperfections like saw blade ripples and edge chipping, while also being labor-intensive and wasteful.
Innovation Solution
A two-bladed saw system that cuts and grinds ceramic logs in a single enclosed operation, using abrasive and non-abrasive regions on the blades to achieve precise cuts and smooth surfaces, with a mechanism for automatic indexing and dust removal, reducing the number of process steps and improving dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If water-cooled single-bladed saw and separate grinding wheels are used, then cutting and grinding can be performed, but the process requires multiple steps and is labor-intensive
Solution Approach 1:
The patent combines cutting and grinding functions into a single blade assembly. The blade has cutting edges on its circumference and grinding surfaces on its sides, allowing both operations to be performed in one pass rather than requiring separate water-cooled saw and grinding wheel equipment
Solution Approach 2:
The blade is designed to perform multiple functions: cutting the ceramic log transversely and grinding the cut surfaces to exact length. This multi-functional blade eliminates the need for separate dedicated cutting and grinding equipment, reducing the number of process steps from four to one
2Temperature
If water-cooled equipment is used for cutting and grinding, then cooling is provided, but water usage increases and dust removal becomes necessary
Solution Approach 1:
The patent extracts the water cooling system from the process and replaces it with dry cutting and grinding using the multi-functional blade. The enclosed housing contains the operation and allows for dust collection and removal without requiring water for cooling, eliminating water consumption and the need for filtration systems
Solution Approach 2:
The patent converts the harmful effect of dust generation during dry cutting into a manageable issue by enclosing the operation and using dust collection systems. The dry cutting process, while potentially generating dust, eliminates water consumption and allows for better control of the working environment through enclosure and filtration
3Productivity
If single-bladed saw is used for cutting, then cutting can be performed, but saw blade ripples and edge chipping occur
Solution Approach 1:
The patent merges cutting and grinding functions into a single integrated blade assembly. The grinding surfaces on the sides of the blade immediately follow the cutting action, removing saw blade ripples and preventing edge chipping in the same operational pass, thereby improving surface quality without sacrificing productivity
4Manufacturing precision
If multiple process steps are used for cutting and grinding, then precision can be achieved, but the process is labor-intensive and time-consuming
Solution Approach 1:
The patent combines cutting and grinding operations into a single blade assembly that performs both functions in one pass. The blade cuts the ceramic log transversely and immediately grinds the cut surfaces to exact length, achieving the same dimensional accuracy as separate processes but with significantly improved productivity and reduced labor requirements
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 approach reduces the number of process steps from four to one, enhances precision and surface quality, eliminates water usage, and allows for automated operation, improving the shape and consistency of fired ceramic pieces by cutting and grinding green ceramic logs before firing.
Implementation Method 1
grinding the cut transverse surface with a side (i.e. transverse surface) of the blade
Data Source
AI summary
Cutting and grinding of ceramic-type logs to a desired piece length is disclosed. A method of manufacturing ceramic ware is disclosed which comprises transversely cutting a piece from a ceramic-type log having a longitudinal axis by cutting into the log with a blade at a location along the length of the log to form a cut transverse surface on the piece and grinding the cut transverse surface with a side of the blade. An apparatus for manufacturing ceramic ware is also disclosed comprising means for transversely cutting a piece from a ceramic-type log having a longitudinal axis, including a blade for cutting into the log at a location along the length of the log to form a cut transverse surface on the piece, and means for grinding the cut transverse surface with a side of the blade.