Modular Tool Support for Cutting Heads

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Solution Overview

Problem

Existing cutting heads in hard rock mining applications require frequent replacement of cutting bits, which can be stuck due to dirt and rock, leading to downtime and increased costs, and lack flexibility and efficiency in tool support configurations.

Innovation Solution

A modular cutting head design with replaceable tool supports and cutting bit carriers that allow for non-removable assembly of cutting bits, using a method where the cutting bit is heated and deformed to fit an undercut section, and tool supports that are releasably mounted to a base member with overlapping configurations for enhanced flexibility and reduced complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If cutting bits are removably supported by cutting bit carriers, then cutting bits can be replaced, but cutting bits get stuck due to dirt and rock requiring frequent replacement and causing downtime

Engineering Contradiction:

Improveease of cutting bit replacementVSAvoiddowntime for cutting bit replacement

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The cutting head is divided into modular components: the base member, multiple tool supports, and cutting bit carriers. Each tool support can be independently replaced, and each cutting bit carrier can be independently replaced on the tool support. This segmentation allows for selective replacement of only the worn component rather than the entire cutting head assembly, reducing downtime and maintenance costs.

Inventive Principle:

Principle #1Segmentation

2Reliability

If cutting bits are non-removably assembled to cutting bit carriers, then cutting bits remain secure during operation, but cutting bits cannot be easily replaced

Engineering Contradiction:

Improveretention of cutting bits during operationVSAvoidease of cutting bit replacement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The cutting bit carrier is pre-configured with a retention mechanism that automatically secures the cutting bit during operation. The carrier includes features such as retention arms or locking mechanisms that engage with the cutting bit shank, providing secure retention without requiring additional assembly steps during operation. This preliminary configuration ensures reliable cutting bit retention while allowing for easy replacement when needed.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If cutting head is designed as integral unit, then manufacturing is simplified, but flexibility in tool positioning is reduced

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidflexibility in tool positioning

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The cutting head is segmented into a base member and multiple interchangeable tool supports that can be mounted in different positions and orientations. Each tool support can be independently positioned to accommodate different cutting configurations. This modular approach provides the flexibility of multiple positioning options while maintaining manufacturing simplicity through standardized components and assembly procedures.

Inventive Principle:

Principle #1Segmentation

4Quantity of substance

If multiple cutting bit carriers are mounted on tool support, then cutting capacity is increased, but complexity of retention system increases

Engineering Contradiction:

Improvenumber of cutting bitsVSAvoidcomplexity of retention system

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

Multiple cutting bit carriers are merged onto a single tool support structure, sharing common mounting features and retention mechanisms. The tool support includes multiple carrier mounting positions with standardized retention features, allowing multiple cutting bit carriers to be secured using the same basic retention system design. This merging approach increases cutting capacity while avoiding proportional increases in system complexity through component standardization and reuse.

Inventive Principle:

Principle #5Merging (Combining)

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 design reduces downtime and costs by allowing for easy replacement of entire tool supports, increases flexibility in tool positioning, and simplifies the retention system, while maintaining the cutting bits' rotational functionality.

Implementation Method 1

heating the cutting bit to a predetermined temperature

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

applying a compression force to the cutting bit along the longitudinal axis for deforming the heated cutting bit

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentEP3004544B1Tool support for cutting heads

Publication Date: 2019.06.19 CATERPILLER GLOBAL MINING EURO GMBH

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AI summary

The present disclosure relates to a replaceable tool support (40; 140) configured to be mounted to a cutting head (10; 110 used in hard rock mining applications. The disclosed tool support (40; 140) may comprise an annular body (90; 190), a plurality of cutting bit carriers (50; 150) disposed spaced apart from each other on a first end face side (92; 192) of the annular body (90; 190), and a plurality of cutting bits (60). Each of the plurality of cutting bits (60) may be rotatably supported by one of the plurality of cutting bit carriers (50). When at least one of the plurality of cutting bits (60) is worn, the tool support (40; 140) including worn cutting bits (60) may be replaced by a new tool support (40; 140) including new cutting bits (60).