Knife Ring Chipper Setup With Robotic Knife Packet Exchange
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Solution Overview
Problem
Existing knife ring shredders face long cycle times, wear and tear issues, and require specific devices for different manufacturers, leading to inefficient maintenance and production risks during repairs.
Innovation Solution
An automated method and device using an industrial robot to remove and install knife packages, including sharpening, with independent sub-areas for disassembly, assembly, and grinding, allowing for high-precision installation and rapid knife pack changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated knife removal and installation is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The system uses automated robots and grinding devices that operate autonomously to remove, sharpen, and reinstall knives without human intervention, enabling continuous operation and dramatically reducing maintenance downtime while improving productivity
Solution Approach 2:
The knife ring maintenance process is divided into three independent sub-areas: knife removal, knife sharpening, and knife reinstallation. This segmentation allows each station to operate independently and simultaneously, improving overall efficiency while managing system complexity through modular design
2Loss of time
If on-site sharpening is performed, then loss of time is reduced, but manufacturing precision deteriorates due to wear of grinding elements
Solution Approach 1:
Traditional manual or portable grinding methods are replaced with a sophisticated automated grinding device featuring programmable control and precision positioning systems. This substitution maintains on-site sharpening capabilities while ensuring consistent, high-precision results through automated control and calibrated grinding parameters
Solution Approach 2:
The grinding device allows for programmable control of grinding parameters such as wheel speed, feed rate, and depth of cut. These parameters can be adjusted and optimized for different knife types and wear conditions, maintaining precision across various operating conditions while enabling rapid processing
3Manufacturing precision
If specialized devices are used for specific knife ring types, then manufacturing precision is improved, but adaptability decreases
Solution Approach 1:
The maintenance device is designed with universal features that allow it to handle different knife ring types and manufacturers. The system can accommodate various knife configurations through adjustable fixtures and programmable parameters, eliminating the need for multiple specialized devices while maintaining precision through adaptive control
4Reliability
If the entire device is taken out of service for maintenance, then reliability is improved, but productivity is worsened due to production shutdown
Solution Approach 1:
The knife ring is divided into multiple knife packages that can be independently removed, sharpened, and reinstalled. This segmentation allows the maintenance process to be performed in sections while the rest of the knife ring remains operational, enabling continuous production while maintaining reliability
Solution Approach 2:
The automated maintenance system operates continuously with multiple stations working in parallel - while some knives are being removed and sharpened, other knives remain in service. The system maintains continuous useful action by ensuring that knife replacement does not require complete shutdown, thus preserving productivity while ensuring reliability through regular maintenance
Data Source
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AI summary
The invention relates to a process for setting up a knife ring of a knife-ring chipper for comminuting materials, wherein in a first part (37) of the process, knife packets (4) consisting of a clamping plate (6) and a blunt knife (2) are removed from a knife ring (1) by an industrial robot (10) and knife packets (5) having a sharp knife (2) are inserted into the knife ring (1), wherein in a second part (38) of the process, knife packets (4) are disassembled into a blunt knife (2) and a clamping plate (6) and sharp knives (3) are assembled using a clamping plate (6) to form a knife packet (5), and wherein in a third part (39) of the process the blunt knives (2) are sharpened to form sharp knives (3). The problem addressed by the invention is that of providing a process and a device in which highly precise arranging of the sharp knives (3) or the knife packets (5) in the knife ring and/or high-speed exchanging of the knife packets of a knife ring is made possible. The invention also relates to a device for setting up a knife ring, which device is also able to solve this problem.