Eccentrically Driven Disc Cutter for Hard Rock Excavation
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Solution Overview
Problem
Traditional rock excavation methods, such as explosive excavation and rolling edge disc cutter technology, face challenges in automation, efficiency, and energy consumption, particularly in excavating hard rock, with explosive methods being cyclic and violent, and mechanical methods requiring high forces and large machinery.
Innovation Solution
The use of an eccentrically driven disc cutter system with multiple disc cutters mounted on an arm, allowing for reduced force application and increased efficiency through tensile fracture of rock, enabling automation and efficient excavation of hard rock with reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If rolling edge disc cutter technology is used for mechanical fragmentation of rock, then automation of excavation process is enabled, but very large forces (about 50 tones per cutter) are required to crush and fragment the rock
Solution Approach 1:
The patent applies mechanical vibration by oscillating the disc cutter between impact and retraction positions. This vibrational motion allows the cutter to fracture rock through repeated small impacts rather than requiring large static crushing forces, enabling automation while reducing the force requirement per cutter
Solution Approach 2:
The disc cutter operates through periodic cycles of impact and retraction. This periodic action allows the cutter to accumulate fragmentation effect over multiple cycles without requiring peak forces high enough to crush the rock in a single impact, thus reducing the force requirement while maintaining automation capability
2Productivity
If multiple cutters are arranged to traverse the rock in closely spaced parallel paths, then excavation coverage is increased, but machinery weight increases to upwards of 800 tones
Solution Approach 1:
The patent segments the cutting function into multiple independently operable disc cutters that can be arranged in parallel. Each cutter operates independently with its own drive mechanism, allowing the system to achieve high excavation coverage through multiple cutters without requiring a single massive machinery platform, thus reducing overall weight while maintaining productivity
3Productivity
If explosive excavation is used for hard rock, then rapid rock fragmentation is achieved, but the process is cyclic and violent preventing automation
Solution Approach 1:
The patent replaces the explosive mechanical system with a controlled mechanical vibration and impact system. Instead of using explosives that create uncontrolled violent fragmentation, the system uses oscillating disc cutters that apply controlled mechanical forces, enabling automation while maintaining rapid rock fragmentation capability
4Duration of action of moving object
If rolling edge disc cutters are used, then continuous operation is enabled, but electrical power consumption is in the order of thousands of kilowatts
Solution Approach 1:
The oscillating disc cutter system uses mechanical vibration to achieve rock fragmentation, which is more energy-efficient than the high-power electrical systems required by traditional rolling edge cutters. The vibration-based mechanism allows continuous operation with lower power consumption by utilizing the kinetic energy of oscillating masses rather than high-power motors
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
The system achieves efficient rock excavation with reduced applied forces, increased output rate, and lower power usage per unit volume of rock removed, facilitating continuous operation and cost-effective mining with the potential for smaller, lighter machinery.
Implementation Method 1
it causes tensile fracture of the rock, instead of crushing the rock. This tensile fracture force applied to the rock is substantially less than that needed with crushing forces
Implementation Method 2
The Sugden device employs a reaction mass of sufficient magnitude to absorb the forces applied to the rock by the disc cutter during each cycle of oscillation
Data Source
AI summary
A mining machine includes a cutting mechanism with an arm, and a substantial weight of more than a thousand pounds attached to the arm. The mining machine also includes a first disc cutter adapted to engage the material to be mined and mounted on a first disc cutter assembly for eccentrically driving the first disc cutter, the first disc cutter assembly being mounted within the substantial weight. The mining machine also includes at least a second disc cutter spaced apart from the first disc cutter assembly and adapted to engage the material to be mined, and mounted on a second disc cutter assembly for eccentrically driving the second disc cutter, the second disc cutter assembly being mounted within the substantial weight.