Continuous Cutting of Sintered Magnet Blocks

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Solution Overview

Problem

Batchwise production methods for cutting sintered magnet blocks into smaller pieces are inefficient due to the need for frequent setup changes, jig mounting and dismounting, heating, and cleaning with organic solvents, leading to significant drops in productivity.

Innovation Solution

A continuous cutting apparatus featuring a guide rail with slits for OD blades, a holder plate with elastically deformable sections to maintain magnet blocks in a stable position, and a coolant supply system, allowing for continuous extrusion and cutting of magnet blocks into desired shapes and sizes without the need for batchwise processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If batchwise production method with fixed clamping is used, then cutting accuracy is maintained, but productivity significantly decreases due to frequent setup changes and cleaning

Engineering Contradiction:

Improvecutting accuracyVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent transitions from static batchwise clamping to dynamic continuous feeding. The linear motion mechanism continuously feeds magnet blocks through the cutting zone, eliminating the need for repeated setup and clamping operations while maintaining cutting accuracy through consistent positioning.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention implements continuous cutting operation where magnet blocks are continuously fed through the cutting zone. This eliminates idle time for setup changes and cleaning operations, maintaining productive action throughout the entire process cycle.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If multiple OD blades are used for continuous cutting, then productivity increases, but device complexity increases due to additional components and setup requirements

Engineering Contradiction:

Improveproduction efficiencyVSAvoidapparatus complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent uses multiple OD blades arranged in sequence along the linear motion path. Each blade performs cutting on successive magnet blocks, allowing continuous high-speed cutting without increasing overall system complexity through modular blade arrangement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The linear motion mechanism serves multiple functions: it feeds magnet blocks continuously, positions them precisely for cutting, and coordinates the timing of multiple OD blades. This single mechanism replaces what would otherwise require separate feeding, positioning, and synchronization systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If frequent cleaning and setup changes are performed, then magnet block quality is maintained, but operational downtime increases

Engineering Contradiction:

Improveproduct qualityVSAvoidoperational downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The continuous feeding mechanism eliminates idle time between cutting operations. Magnet blocks are continuously supplied and processed without interruption for setup changes or cleaning, maintaining both productivity and product quality through uninterrupted operation.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Magnet blocks are pre-positioned on the linear motion feed mechanism before reaching the cutting zone. This preliminary positioning ensures they are ready for immediate cutting without requiring setup changes, reducing operational downtime while maintaining quality standards.

Inventive Principle:

Principle #10Preliminary action

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 significantly increases productivity by eliminating the need for setup changes and cleaning, ensuring high dimensional accuracy and efficient production of magnet pieces with reduced operational downtime.

Implementation Method 1

multiple OD blades 2 (six blades in the figure) are rotated in the arrow direction... the magnet blocks 1 together with the carbon jig 101 are continuously cutoff machined by the rotating blades 2

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

a coolant is supplied to the cutting site from a coolant supply nozzle 3

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

A plurality of magnet blocks 1 (twenty blocks in the figure) are arranged in cascade and adhesively secured to the carbon jig 101

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 4

the jig is heated again to melt the wax, and the magnet pieces 11 are removed from the jig 101

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS10427219B2Apparatus for continuously cutoff machining sintered magnet blocks

Publication Date: 2019.10.01 SHIN ETSU CHEMICAL CO LTD

AI summary

The continuous cutting apparatus includes a guide rail (5), an extruder (3) for extruding and moving forward a series of sintered magnet blocks (1) on the guide rail (5), a holder plate (6) for holding the magnet blocks in place, and a plurality of OD blades (2) for cutoff machining the magnet blocks into magnet pieces. The cutting apparatus is capable of continuously cutoff machining magnet blocks each into a multiplicity of magnet pieces of desired shape and/or size, achieving a significant increase in productivity and ensuring efficient production of magnet pieces.