Modular Roller Sections for Diamond Wire Cutting Machines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing roller or drum designs for multi-wire machines used in cutting blocks of artificial or natural stone face challenges in compensating for different sliding speeds between diamond wires, leading to uneven wear and high maintenance costs, as well as difficulties in arranging wires for desired slab thickness.
Innovation Solution
A modular roller or drum design with subdivided supporting axes and tubular pivots, allowing sections to be separately connected or joined, with aligned external cylindrical surfaces for uniform groove spacing and easy replacement of worn parts, enabling flexible assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single roller or drum with a complete soft material covering is used, then the grooves provide continuous support for multiple diamond wires, but the entire covering must be replaced when any groove wears, increasing maintenance costs and complexity
Solution Approach 1:
The roller or drum is divided into multiple independent sections, each with its own soft material covering and grooves. When one section's covering wears, only that specific section needs to be replaced rather than the entire roller covering, significantly reducing maintenance costs and complexity while maintaining continuous wire support across all sections.
2Manufacturing precision
If the soft material covering is rigidly connected to the roller or drum, then the grooves maintain precise positioning, but the covering cannot compensate for speed differences between adjacent diamond wires, leading to increased wear
Solution Approach 1:
The soft material covering is made detachable and replaceable in modular sections rather than being rigidly and permanently fixed. This allows the covering to be dynamically adjusted and replaced independently in worn sections, enabling compensation for wear while maintaining precise groove positioning through proper installation and alignment of each modular section.
3Reliability
If complete vulcanization of the soft material covering is performed, then the covering achieves correct hardness and durability, but the process is complex and requires workshop conditions, making on-site replacement impossible
Solution Approach 1:
The soft material covering is divided into modular sections that can be independently removed and replaced. Each pre-manufactured section undergoes complete vulcanization in the factory under controlled workshop conditions, ensuring correct hardness and durability. During maintenance, only the worn modular section needs to be replaced on-site without requiring vulcanization equipment, making maintenance accessible even in field conditions.
4Stability of the object's composition
If sections of the roller are connected rigidly, then the structure maintains stability, but adjustment of wire spacing for different slab thicknesses becomes difficult
Solution Approach 1:
The sections of the roller are connected through adjustable mechanisms rather than rigid fixed connections. This allows the distance between sections to be dynamically adjusted to change wire spacing for different slab thickness requirements, while the connected structure maintains sufficient stability during operation to ensure reliable wire support and cutting performance.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A roller or drum for support and/or guide of diamond wires in multi-wire machines for cutting blocks of artificial or natural stone, comprising: rotating support organs the roller or drum on a pivot or axis of support; a covering (8) made from soft material equipped with grooves (7, 9) for housing, supporting and guiding closed loop adjacent diamond wires; and it is characterized in that the roller or drum in subdivided into at least two sections (2, 3, 4, 32 or 42) or roller or drum constituting at least two parts of roller or drum, for supporting and guiding a number of adjacent diamond wires equal to or more than two per part of roller or drum; correspondingly, each section has its respective part or roller or drum equipped with supporting and rotating organs for each part which are independent and connected to a supporting and rotating axis or pivot of the roller or drum. In a form of construction, the supporting axis or pivot is subdivided into parts of supporting axis or pivot of a width corresponding to the width of the parts of roller of the said sections (2, 3, 4 or 32); the rotating support organs on the corresponding part of supporting axis or pivot allow the section of roller or drum to be separate or joined to the adjacent sections by means of the connection/assembly parts of supporting axis or pivot drawn together. In a further form of construction, the dismantling of the hub (46) and the relative rotating modular body (41 ) of part/section (42) occurs by means of the dismantling of a flange coupling equipped with ears (44, 45) connected through openings (51) and grooves (48) in the opposite flange.