Cutting Head Asymmetric Button Arrangement Prevents Rock Tracking
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Solution Overview
Problem
Conventional rock cutting machines are not optimized to cut hard rock with strengths beyond 120 MPa, leading to increased load cycles and cutter wear due to the 'tracking' problem, where cutters follow existing grooves rather than creating new ones, resulting in inefficient rock removal and premature wear.
Innovation Solution
The cutting apparatus features a cutting head with multiple types of cutter units arranged circumferentially, each with a unique button arrangement to prevent tracking, allowing successive cutters to abrade new rock paths, reducing load cycles and wear by ensuring each cutter has a different button configuration from its predecessor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cutting machines use standard cutter arrangements, then the machine structure is simple and easy to manufacture, but the cutters suffer from tracking problem causing increased load cycles and premature wear
Solution Approach 1:
The patent applies asymmetry by arranging buttons on cutters in non-uniform, asymmetric patterns rather than symmetric distributions. Each cutter has a unique asymmetric button arrangement that prevents following the groove pattern of previous cutters, thereby eliminating the tracking problem and reducing cutter wear while maintaining manufacturing feasibility.
Solution Approach 2:
The patent implements local quality by varying the button arrangement characteristics (position, spacing, pattern) locally on each cutter according to its specific position in the cutting sequence. This localized optimization ensures that each cutter is specifically configured to avoid tracking the groove created by its predecessor, improving reliability without requiring complete redesign of all cutters.
2Productivity
If cutters are arranged to cut hard rock effectively, then rock removal efficiency improves, but the number of load cycles increases due to tracking problem
Solution Approach 1:
By implementing asymmetric button arrangements on cutters, the patent prevents the formation of repetitive groove patterns that cause tracking. This allows cutters to efficiently remove hard rock by creating varied cutting paths, reducing the number of load cycles needed while maintaining high rock removal efficiency.
Solution Approach 2:
The patent changes the geometric parameters of button arrangements (positions, spacing angles, radial distances) on different cutters to optimize rock cutting performance. These parameter variations prevent tracking while maintaining effective rock removal, thereby reducing load cycles and improving productivity simultaneously.
3Reliability
If multiple types of cutter units with different button arrangements are used, then tracking is prevented and cutter wear is reduced, but manufacturing and assembly complexity increases
Solution Approach 1:
The patent applies local quality by implementing different button arrangements only on specific cutters where they are most needed to prevent tracking, rather than making all cutters unique. This selective approach extends cutter life by preventing wear while minimizing manufacturing and assembly complexity through standardized designs for non-critical cutters.
Solution Approach 2:
The patent segments the cutter fleet into different types based on their position and function in the cutting sequence. By grouping cutters with similar requirements, the patent reduces the number of unique designs needed, making manufacturing and assembly more straightforward while still preventing tracking through strategic variation of button arrangements on key cutters.
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 configuration significantly reduces the number of load cycles required to remove rock, decreases cutter fatigue and wear, and allows for efficient cutting of hard rock with a variable cross-sectional area, while being cost-effective and easy to manufacture.
Implementation Method 1
Each cutter includes a disc body and an arrangement of hard buttons for abrading the rock
Implementation Method 2
the number of load cycles required to remove a given amount of rock is significantly higher than it should be. Furthermore since there are a high number of load cycles this tends to fatigue and wear the cutters more than is necessary
Implementation Method 3
a plurality of rotating heads are capable of being slewed laterally outward and raised in the upward and downward direction during forward cutting
Data Source
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AI summary
A cutting head (128) for cutting apparatus (100) suitable for creating tunnels or subterranean roadways and the like. The cutting head (128) having: a rotatable cutting head body (131); a plurality of cutting units (700A,700B) mounted on the cutting head body (131), said cutting units (700A,700B) including at least first and second different types of cutting units (700A,700B), the first type of cutting unit (700A) having a first rotatable cutter (127A) comprising a first disc body (711A) and a first arrangement of buttons (710A) for abrading rock, said first buttons (710A) are mounted in a radially peripheral portion (738) of the disc body and protrude outwardly therefrom, and the second type of cutting unit (700B) having a second rotatable cutter (127B) comprising a second disc body (711B) and a second arrangement of buttons (710B) for abrading rock, said second buttons (710B) are mounted in a radially peripheral portion (738B) of the disc body and protrude outwardly therefrom; wherein the different types of cutting units (700A,700B) are different from one another by at least the arrangements of their buttons (710A,710B).