Endless abrasive belt smoothing with passive regeneration
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Solution Overview
Problem
Existing ceramic surface smoothing technologies face challenges such as high installation and maintenance costs, complex robot manipulation, difficulty with concave surfaces, frequent tool cleaning, and material splashing with current abrasive belts and rotary tools.
Innovation Solution
A smoothing apparatus featuring a power-driven endless abrasive belt with a regenerating passive section, liquid spraying, and suction means, allowing the belt to move around the product while maintaining the product stationary, enabling efficient smoothing of various shapes and sizes with continuous belt regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the semi-finished product is moved into contact with the stationary abrasive belt, then the smoothing operation can be performed, but the robot must handle heavy weights resulting in high installation and maintenance costs
Solution Approach 1:
The patent inverts the conventional arrangement by making the abrasive belt movable and the product stationary. The belt is trained around pulleys and can be moved into contact with the product, reversing who moves and who stays fixed. This eliminates the need for heavy robot manipulation while maintaining smoothing effectiveness.
Solution Approach 2:
The abrasive belt serves as an intermediary element between the product and the smoothing action. Instead of directly moving the product against a fixed belt, the system uses the movable belt as a mediator that can be positioned and moved independently, reducing the weight burden on the robot.
2Reliability
If the abrasive belt is stationary and the product is moved, then the smoothing can be performed, but the apparatus is much lighter than the product leading to high running and maintenance costs
Solution Approach 1:
The patent reverses the conventional setup by making the abrasive belt movable rather than stationary. This inversion allows the lighter belt to be moved by a smaller, more economical robot, reducing running and maintenance costs while maintaining the smoothing function.
3Reliability
If the abrasive belt method is used, then smoothing can be performed, but it is considerably difficult or impossible if the surfaces are concave
Solution Approach 1:
The abrasive belt is made dynamic and flexible rather than rigid and stationary. The belt can be moved and positioned to access various surface geometries including concave areas, making the system adaptable to different product shapes and surface types.
Solution Approach 2:
The abrasive belt functions as a flexible thin film that can conform to and reach into concave surfaces and complex geometries, unlike rigid stationary belts. This flexibility enables the system to handle a wide variety of surface types effectively.
4Reliability
If different effectors are provided for each product, then the manipulation can be performed, but the number of different effectors required increases with wider product range
Solution Approach 1:
The movable abrasive belt system serves as a universal tool that can be applied to a wide range of products and surface types. Instead of requiring specialized effectors for each product type, the single flexible belt mechanism can adapt to handle diverse ceramic products through its mobility and conformability.
5Reliability
If the tank for belt regeneration is positioned in fixed orientation, then the regeneration can be performed, but the versatility of the installation is considerably limited
Solution Approach 1:
The belt regeneration system is made dynamic and repositionable rather than fixed. The tank and associated regeneration equipment can be moved and repositioned to accommodate different product configurations and optimal operating conditions, enhancing installation versatility.
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 solution reduces the weight and cost of robotic manipulation, allows for effective smoothing of concave surfaces, minimizes tool cleaning frequency, and prevents material splashing, enhancing productivity and versatility in ceramic product finishing.
Implementation Method 1
The apparatus also comprises means located in the vicinity of the belt for spraying a liquid on the belt which has liquid absorption properties
Implementation Method 2
The apparatus also comprises suction means associated with the passive section of the belt and operating in such a way as to remove the liquid and the process waste materials retained by it
Implementation Method 3
The particles of ceramic material removed are trapped in the material structure of the abrasive belt's active section
Data Source
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AI summary
An apparatus (1) for smoothing a product (2), in particular a semi-finished ceramic product, comprises: an abrasive tool (3) in the form of an endless belt (4) which is trained around at least one pair of pulleys (5, 6), at least one of which is power-driven; the belt (4) has an active section (7) and at least one passive section (8); the active section (7) removes material from the product (2), while the passive section (8) receives a regenerating treatment that restores the abrasive capacity of the tool (3); drive means (20) acting on the belt (4) in such a way as to enable the belt (4) itself to move in the space surrounding the product (2); means (10) for spraying a liquid on the belt (4), which has liquid absorption properties, said means (10) being located in the vicinity of the belt (4) itself; and negative pressure means (9) associated with the passive section (8) of the belt (4) and operating in such a way as to extract the liquid and the materials retained by the belt (4) and removed from the product (2) during the smoothing process.