Mini-Blade with Transversal Tab for Pneumatic Roughing
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Solution Overview
Problem
Conventional retreading blades for pneumatics have a significant material waste issue due to the majority of the blade being used for clamping rather than scraping, leading to inefficiencies in energy consumption and environmental impact, and deformation during thermal treatment complicates assembly and increases costs.
Innovation Solution
A mini-blade with a reduced size where the clamping part is smaller than the working part, featuring a transversal tab for secure clamping without slots or openings, and a modular clamping set with peripheral tabs and sockets for uniform force distribution, reducing material usage and preventing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional blades are used for retreading pneumatics, then the blade can be mounted and clamped securely, but the majority of the blade body is directed to mounting and clamping rather than scraping work, causing material waste
Solution Approach 1:
The blade is segmented into distinct functional zones: a minimal clamping portion (tab) and a maximal working portion (scraping edge). This segmentation allows the blade body to be optimized for scraping rather than clamping, with the clamping function performed by a separate tab structure that does not interfere with the scraping geometry.
Solution Approach 2:
The clamping function is extracted from the main blade body and implemented through a dedicated tab structure. This extraction allows the blade body to be minimized to only the necessary scraping portion, while the tab handles all mounting and clamping operations, thereby reducing material waste in the working portion.
2Ease of manufacture
If conventional blades with slots and openings are used for mounting, then the blade can be secured to the device, but the presence of openings increases deformation possibilities during thermal treatment, making assembly difficult
Solution Approach 1:
The mounting openings and slots are extracted from the blade body and relocated to the tab structure. The tab contains all necessary mounting features (openings, slots, holes) while the blade body remains solid and uninterrupted, preventing deformation during thermal treatment and ensuring manufacturing precision.
Solution Approach 2:
Different parts of the blade have different structural qualities: the blade body is solid and uninterrupted to maintain flatness and resist deformation during thermal treatment, while the tab contains all mounting openings and features to facilitate assembly. This local differentiation of structural quality resolves the contradiction between assembly ease and manufacturing precision.
3Manufacturing precision
If the blade body is made with great thickness to reduce deformation during thermal treatment, then the blade maintains its plane, but the clamping portion becomes larger and more material is wasted
Solution Approach 1:
The blade is segmented into a thin blade body optimized for scraping and a separate tab structure optimized for clamping. The tab can be made with sufficient thickness to maintain plane during thermal treatment without increasing the thickness of the blade body, thereby minimizing material usage in the working portion while maintaining manufacturing precision.
4Productivity
If conventional blades are used, then the blade can perform scraping work, but 5,000 Kw/h of electric power are needed to produce 1 Tn of steel, generating significant environmental pollution
Solution Approach 1:
The invention implements a feedback loop where the actual scraping requirement (minimal contact width) is measured and used to optimize the blade geometry. By reducing the blade dimensions to the minimum necessary for scraping function, the steel production requirements are reduced, thereby reducing environmental pollution from steel manufacturing.
Solution Approach 2:
The blade parameters (length, width, thickness) are changed to minimal values necessary for scraping function. This parameter optimization reduces the total steel volume required, directly reducing the environmental impact of steel production (5,000 Kw/h per ton) while maintaining scraping work capability.
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 mini-blade design achieves at least 30% less steel usage, reduces energy consumption during thermal treatment, prevents breakage from impurities, and provides a stronger, more uniform clamping structure, making it more cost-effective and environmentally friendly while maintaining structural integrity.
Implementation Method 1
blades are processed with 'raw' materials (malleable non-tempered steel). Once they are shaped, a thermic treatment is conducted granting them the necessary hardness to be able to work. During this treatment (heating at 800° C. and further cooling at 120° C.)
Implementation Method 2
a uniform clamping is reached thanks to the presence of a transversal tab and its adjacent clamping portions, which allows it to adequately support both the centripetal forces and the centrifugal forces that operate uniformly over all the laminar body
Implementation Method 3
The absence of fixing openings prevents weakening in the clamping part of the mini-blade which, at the same time, prevents breakage of the blades when hits owed to pulls because of the presence of impurities embedded in the coatings to rough down are produced
Data Source
AI summary
The present invention refers to a mini-blade (1) which body (2) has an inner edge (4) in which there is, at least, one transversal tab (6) that constitutes a retention means of the mini-blade (1) in an adapter device (20); between the inner (4) and the external (3) edges, the body (2) has the sufficient extension to form clamping portions (7)(8) that allow the application of clamping peripheral tabs (30). The invention also refers to an adapter device (20) that, for the mounting of a rotary work structure (40) of pneumatic roughing down, includes clamping sets (20) composed of ending supports (21)(22) and intermediary separator supports (23), all of which have clamping transversal peripheral tabs (30) that form jaws capable of clamping the clamping positions (7)(8) of the mini-blade (1). The different supports (21)(22)(23) that form the clamping sets (20) are arranged attached one to another, in train, with the mini-blades (1) interspersed in their jaws, in such a way that the toothed external edge (3) of these last ones protrudes from the clamping set (20).