Removable Mower Blade Insert with Tab and Pocket
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Solution Overview
Problem
The existing mower blades require cumbersome and difficult removal and replacement processes, especially for larger commercial mowers, as they are heavy and require large tools for dislodging and reattaching, making it challenging for a single individual to sharpen or replace the blades without aligning and holding the bulky blade in place.
Innovation Solution
A mower blade assembly with a main body and a removably attachable blade insert featuring a mounting tab and pocket system, allowing for easy sliding and securing of the blade insert without needing to remove the entire blade from the rotating shaft, using a smaller fastener that requires less torque and allows hands-free operation during replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire blade is removed from the rotating shaft for sharpening or replacement, then the cutting surfaces can be maintained or replaced, but the process requires large tools, high torque, and is difficult for a single individual to perform
Solution Approach 1:
The blade is divided into two main segments: a main body that remains attached to the rotating shaft, and a blade insert that can be independently removed and replaced. This segmentation allows the cutting surfaces (on the insert) to be maintained without removing the entire blade assembly, eliminating the need for large tools and high torque operations.
Solution Approach 2:
The cutting surfaces are extracted from the main blade body and placed on a separate blade insert. This insert can be removed and replaced independently by simply unscrewing a small fastener, allowing single-person maintenance without the need to handle the heavy main blade assembly.
2Strength
If large diameter bolts are used to couple the blade to the rotating shaft, then the blade is securely fastened, but removal and replacement requires large tools and significant torque
Solution Approach 1:
The attachment system is segmented into two parts: large diameter bolts that secure the main blade body to the rotating shaft (providing strong attachment), and a separate small fastener that secures the blade insert to the main body (allowing easy removal). This segmentation enables secure operation during use while facilitating easy maintenance.
Solution Approach 2:
The fastening function is extracted and separated into two distinct fastening mechanisms: the large diameter bolts for the main body attachment (providing strength), and a small fastener for the blade insert (enabling ease of repair). This allows the weak fastener to be used only for the lightweight insert while the strong bolts remain in place.
3Ease of repair
If the entire blade is removed for replacement, then damaged blades can be replaced, but the process is cumbersome and requires aligning and holding the bulky blade in place
Solution Approach 1:
The blade system is segmented into a heavy main body that remains stationary on the shaft and a lightweight blade insert that is easily handled. This segmentation reduces the weight and bulk of the component that must be removed and replaced, making the process suitable for single-person operation.
Solution Approach 2:
The blade insert is extracted as a separate, lightweight component that contains only the cutting surfaces. This extracted insert weighs significantly less than the complete blade assembly, eliminating the need for two-person handling and complex alignment procedures.
4Ease of operation
If the blade insert includes a mounting tab and pocket system with an opening defined by a closed perimeter, then the insert can be easily secured to the main body, but the design complexity increases
Solution Approach 1:
The mounting tab and pocket system is designed to be self-aligning and self-securing. The closed perimeter opening in the mounting pocket automatically guides and positions the mounting tab during insertion, eliminating the need for complex alignment procedures or additional alignment features. The geometry of the tab and pocket themselves provides the alignment function.
Data Source
AI summary
A mower blade assembly, a mower including such an assembly, and methods of replacing a blade insert of the mower blade assembly are disclosed. The mower blade assembly includes a main body and a blade insert removably attachable to the main body between an operable position and a removed position. One of the main body and the blade insert includes a mounting tab and the other of the main body and the blade insert includes a mounting pocket sized and shaped to receive the mounting tab when the blade insert is in the operable position. The mounting pocket includes an opening being defined by a closed perimeter provided in an end face of the other of the main body and the blade insert. The method includes slidably coupling the blade insert to the main body of the mower blade, and removably securing the blade insert to the main body.