Horizontal Cutter Disk Grinding System

Solution Overview

Problem

Existing horizontally fed grinding systems face challenges such as lack of gravity to advance material, non-uniform grinding mechanisms, and rapid dulling of cutter systems, leading to inefficiencies and safety concerns, particularly when processing large or hard materials.

Innovation Solution

A portable grinding machine with a trailer-mounted system featuring a grind hub and cutter disk that rotates at an offset angle, combined with oscillating plates and a conveyor system to efficiently advance and process bulk materials, ensuring uniform grinding and safety through adjustable output sizes and reduced force requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If vertical grinding systems with hammers are used to smash bulk material, then the material is broken down into smaller particulate material, but much more force and power (two to four times the amount of energy) is required to operate these systems

Engineering Contradiction:

Improvematerial breakdown efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent inverts the conventional vertical hammering approach by using a horizontal cutting configuration. Instead of smashing material vertically with hammers, the system uses a horizontally rotating cutter disk with blades that cut through material fed horizontally, reversing the orientation and mechanism to reduce energy consumption while maintaining productivity.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces the mechanical hammering system with a cutting system. Instead of using impact forces from hammers to break material, the system uses a rotating cutter disk with blades that mechanically cut through the material, substituting one mechanical mechanism for another more efficient one.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If vertical grinding systems with hammers are used to smash bulk material, then the material is broken down into smaller particulate material, but the hammers on the grinding wheels will occasionally fail, break off the wheel, and go flying through the air, seriously injuring or even killing people

Engineering Contradiction:

Improvematerial breakdown efficiencyVSAvoidsafety hazards from projectile components

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent inverts the conventional vertical hammering approach by using a horizontal cutting configuration. Instead of smashing material vertically with hammers, the system uses a horizontally rotating cutter disk with blades that cut through material fed horizontally, reversing the orientation and mechanism to reduce energy consumption while maintaining productivity.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces the mechanical hammering system with a cutting system. Instead of using impact forces from hammers to break material, the system uses a rotating cutter disk with blades that mechanically cut through the material, substituting one mechanical mechanism for another more efficient one.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If legacy horizontal grinding systems are used, then gravity cannot be leveraged to push bulk material towards the grinding wheel, but these systems have problems due to a lack of uniform grinding mechanisms and cutter systems that dull quickly

Engineering Contradiction:

Improvematerial advancement without gravityVSAvoiduniformity of grinding

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent applies dynamics by making the cutter disk rotate horizontally rather than remain stationary or rotate vertically. This dynamic horizontal rotation of the cutter disk, combined with horizontal material feed, creates uniform cutting action throughout the material batch, solving the uniformity problem while maintaining ease of operation.

Inventive Principle:

Principle #15Dynamics

4Device complexity

If conventional horizontal grinding systems feed material to a single stationary wheel, then the system is simple, but this limits the size of the feed opening and prevents processing of larger bulk materials

Engineering Contradiction:

Improvesimplicity of single stationary wheelVSAvoidfeed opening size

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent applies dynamics by making the cutter disk rotate horizontally rather than remain stationary or rotate vertically. This dynamic horizontal rotation of the cutter disk, combined with horizontal material feed, creates uniform cutting action throughout the material batch, solving the uniformity problem while maintaining ease of operation.

Inventive Principle:

Principle #15Dynamics

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 effectively processes large volumes of materials with reduced energy consumption and enhanced safety by utilizing oscillating plates and a conveyor system to manage material flow, providing efficient and uniform grinding while minimizing the risk of component failure and injury.

Implementation Method 1

a cutter disk coupled to the grind hub and structured to rotate about a cutter disk axis, the cutter disk axis being offset from the grind hub axis

Methodology Applied

Scientific EffectMechanical cutting: Mechanical Force

Implementation Method 2

a plurality of plates coupled to the tray and structured to slide along the tray back and forth towards the cutter disk and away from the cutter disk, wherein the plurality of plates includes a first row of plates and a second row of plates, the first row of plates and the second row of plates structured to oscillate relative to each other

Methodology Applied

Scientific EffectOscillatory motion: Harmonic Oscillator

Implementation Method 3

the conveyor including a belt that transports ground particulate matter away from the cutter disk and grind hub

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 4

the conveyor including a belt that transports ground particulate matter away from the cutter disk and grind hub

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS11745188B2Horizontally fed disk grinding system and method

Publication Date: 2023.09.05 COMCORP INC

AI summary

A horizontally fed disk grinding system includes a tray coupled to a trailer for receiving bulk material. The system further includes a grind hub coupled to the trailer and a cutter disk coupled to the grind hub. The grind hub is structured to rotate about a grind hub axis and the cutter disk is structured to rotate about a cutter disk axis and about the grind hub axis. A grind ring is coupled to the trailer and is structured to slide to engage the grind hub during use. A plurality of plates are coupled to the tray and structured to oscillate to feed material from the tray to the grind hub and the cutter disk, where the material is reduced to particulate form. The grind hub further includes an outlet and a conveyor rotatably coupled to the trailer to convey the particulate material away from the outlet to a selected location.