Powered Shearing Apparatus for Protrusion Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power tools for removing material protrusions from surfaces often damage the substrate, fail to completely remove the protrusion, and are time-consuming, with manual tools limited by operator strength and endurance.
Innovation Solution
A powered apparatus with a shearing block and cutting blade system that allows for controlled relative movement within a flat plane, utilizing a hydraulic actuator for precise cutting and retraction, and a momentary switch for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If power tools are used to remove material protrusions, then removal speed increases, but substrate damage occurs due to excessive temperature or physical marring
Solution Approach 1:
The cutting action is segmented into two distinct edges: a shearing edge that engages the first portion of the protrusion and a cutting edge that clips the opposing portion. This segmentation allows each edge to perform a specialized function, with the shearing edge providing initial engagement and the cutting edge completing the removal, thereby reducing overall cutting time and substrate damage.
Solution Approach 2:
The shearing block acts as an intermediary element between the protrusion and the cutting blade. The shearing edge on the shearing block engages the protrusion first, positioning and pre-cutting the material before the cutting blade's cutting edge completes the removal. This intermediary action reduces the direct contact time and force between the cutting blade and substrate, minimizing damage.
2Object-affected harmful factors
If conventional cutting tools are used, then substrate damage is minimized, but removal time increases and economic viability decreases
Solution Approach 1:
The cutting operation is divided into two simultaneous actions performed by two different edges: shearing and cutting. This segmentation allows both actions to occur in parallel rather than sequence, significantly reducing total removal time while maintaining the gentle action of shearing that protects the substrate.
Solution Approach 2:
The invention merges two different cutting mechanisms (shearing and clipping) into a single integrated apparatus. The shearing block with its shearing edge and the cutting blade with its cutting edge work together in coordinated fashion, combining the benefits of both shearing (substrate protection) and clipping (speed) in one operation.
3Ease of operation
If manual tools are used for protrusion removal, then operator control is maintained, but removal capability is limited by physical strength and endurance
Solution Approach 1:
The manual mechanical advantage system is replaced with a hydraulic actuator system. The actuator with piston and cylinder provides powered movement of the cutting blade, eliminating the need for operator physical strength while maintaining precise control through the confined range of motion and parallel guidance mechanism.
Solution Approach 2:
A hydraulic actuator is used to provide the cutting force, replacing manual mechanical effort. The actuator's piston and cylinder mechanism converts hydraulic pressure into controlled linear motion, enabling the cutting blade to engage and retract with sufficient force without being limited by operator endurance.
4Reliability
If the cutting edge engages deeply to ensure complete removal, then protrusion removal is complete, but substrate damage increases
Solution Approach 1:
The removal process is segmented into two stages: the shearing edge engages first to cut through the protrusion material, and the cutting edge completes the removal by clipping the opposing portion. This segmentation ensures complete removal while limiting the depth and duration of engagement at any single point, thereby protecting the substrate.
Solution Approach 2:
The shearing edge performs a partial cut on the first portion of the protrusion, and the cutting edge performs a partial cut on the opposing portion. Neither edge needs to engage the full depth of the protrusion alone, as their combined partial actions achieve complete removal with reduced individual engagement depth, minimizing substrate damage.
5Object-affected harmful factors
If the cutting tool is designed for precision to avoid substrate damage, then substrate protection is improved, but removal speed decreases
Solution Approach 1:
The precision cutting function is segmented between two edges with different characteristics. The shearing edge provides precise initial engagement with controlled action, while the cutting edge provides the final clipping action. This segmentation allows each edge to be optimized for its specific function, maintaining precision while increasing overall speed.
Solution Approach 2:
The shearing edge performs a preliminary cutting action on the first portion of the protrusion before the cutting edge engages. This preliminary action reduces the material that the cutting edge must remove, allowing the cutting edge to work more quickly and efficiently while the shearing edge maintains precision and substrate protection.
Data Source
AI summary
An apparatus for clipping a protrusion of material is provided. The protrusion may, for example, be a bolt head, a nut, a rivet, a weld bead, or a temporary assembly alignment tab protruding from a substrate surface of assembled components. The apparatus typically includes a cleaver having a cleaving edge and a cutting blade having a cutting edge. Generally, a mounting structure configured to confine the cleaver and the cutting blade and permit a range of relative movement between the cleaving edge and the cutting edge is provided. Also typically included is a power device coupled to the cutting blade. The power device is configured to move the cutting edge toward the cleaving edge. In some embodiments the power device is activated by a momentary switch. A retraction device is also generally provided, where the retraction device is configured to move the cutting edge away from the cleaving edge.