Abrasive Roller With Interlocking Elements

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Solution Overview

Problem

Traditional abrasive rollers for processing stone and composite materials face issues such as high production costs, long assembly times, and the need for precise welding, which can lead to misalignment and reduced material removal efficiency.

Innovation Solution

The development of an abrasive roller composed of removable and interlocking abrasive elements, which are assembled without welding, using a support body with shaped grooves and counter-shaped means for secure engagement, allowing for quick and simple assembly and customization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding is used to attach abrasive elements to the roller body, then the abrasive elements are securely fixed, but the production cost increases and assembly time becomes lengthy

Engineering Contradiction:

Improvesecure fixation of abrasive elementsVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the welding process (thermal/chemical system) with a mechanical interlocking system using shaped grooves and corresponding protrusions on the abrasive elements. This mechanical substitution eliminates the time-consuming welding operation while maintaining secure fixation of the abrasive elements to the roller body.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The roller is divided into modular components: the roller body with shaped grooves and separate abrasive elements with corresponding engagement features. This segmentation allows independent manufacturing and assembly without welding, reducing both production time and complexity while maintaining structural integrity through the interlocking mechanism.

Inventive Principle:

Principle #1Segmentation

2Reliability

If welding is used to attach abrasive elements, then secure fixation is achieved, but production cost increases due to welding materials and process complexity

Engineering Contradiction:

Improvesecure fixation of abrasive elementsVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent eliminates welding processes and associated costs (welding materials, specialized equipment, skilled labor) by implementing a purely mechanical interlocking system. The shaped grooves and protrusions provide secure fixation through geometric constraints alone, significantly reducing manufacturing complexity and cost.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The abrasive elements are designed as inexpensive, replaceable components that can be easily manufactured without expensive welding processes. When worn, these elements can be quickly replaced without requiring costly welding operations, making the overall system more economically viable.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If traditional welding methods are used, then abrasive elements are fixed to the roller, but misalignment may occur reducing material removal efficiency

Engineering Contradiction:

Improvefixation of abrasive elementsVSAvoidalignment of abrasive elements

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent employs asymmetric shaped grooves and corresponding protrusions that provide built-in alignment features. The geometric asymmetry ensures that abrasive elements can only be installed in the correct orientation, eliminating misalignment issues that occur with symmetric welding fixtures and ensuring optimal material removal efficiency.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The alignment features (shaped grooves and protrusions) are pre-formed during manufacturing, providing built-in alignment guidance before assembly. This preliminary preparation of alignment features ensures precise positioning of abrasive elements without requiring complex alignment procedures during the assembly process.

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 solution eliminates the need for welding, reduces production costs, and simplifies assembly, enabling faster and more efficient material removal with reduced risk of misalignment, while allowing for easy replacement and customization of abrasive elements.

Implementation Method 1

The roller according to the invention can be used for calibrating, roughing, smoothing, grinding, grinding, squaring and/or chamfering of products... in natural stone materials, for example marble or granite or other natural stones, or agglomerates, for example in quartz agglomerate, or in synthetic or sintered stone

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentEP4066997A1An improved roller

Publication Date: 2022.10.05 MEGGIORIN ANDREA

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AI summary

Abrasive roller (1) for processing products in mineral and/or synthetic material, composite or not, comprising a plurality of abrasive elements (2), superimposed and packed together, which are removably engaged by interlocking a central and internal support body (3) and/or to other mounting structure (4) which is associated with said support body (3); characterized in that it comprises shaped hooking means made in a single body with said support body (3) and/or with said mounting structure (4); each abrasive element (2) shaped as a sector of an annulus comprises an internal edge (11) in which counter-shaped means (16) are obtained, mechanically engaged in a shape relationship in a removable manner with said shaped coupling means.