Refining Segment Assembly for Dense Bar Surface Manufacturing
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Solution Overview
Problem
The manufacturing of refining segments for fibrous material refinement, particularly those with very dense surface configurations, faces challenges such as limited mould accuracy in casting, incomplete filling, and high surface roughness, as well as excessive welding work required for metal strip-based methods.
Innovation Solution
The method involves using profiled wires with varying widths to form refining bars and grooves, which are arranged immovably next to each other to create refining bar elements fastened onto a back plate with a solidifying substance, eliminating the need for extensive welding and enabling precise, dense surface configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If casting method is used to manufacture refining segments, then manufacturing process is simple, but manufacturing precision deteriorates due to limited mould construction accuracy making very dense refining surface configurations impossible
Solution Approach 1:
The refining surface is divided into multiple refining segments that can be manufactured separately and then assembled. Each segment contains refining bars and grooves that can be precisely formed, and multiple segments are arranged to create the complete refining surface with very dense configurations that would be impossible to achieve with a single cast piece.
Solution Approach 2:
The refining bars and grooves are pre-formed on the refining segments before final assembly. The segments are manufactured with precise dimensions and surface configurations using methods that allow high precision, then these pre-formed segments are assembled to create the complete refining surface.
2Productivity
If casting method is used to manufacture refining segments, then production time is reduced, but manufacturing precision deteriorates due to incomplete filling and high surface roughness that cannot be corrected after casting
Solution Approach 1:
The refining surface is divided into multiple refining segments that can be manufactured separately. Each segment can be produced with controlled surface finish quality, and defects can be addressed on individual segments rather than requiring re-casting of the entire surface.
Solution Approach 2:
The refining bars and grooves are pre-formed on the segments with precise surface finishes before assembly. This preliminary formation allows for quality control and surface treatment to be applied to each segment individually, ensuring high surface finish quality while maintaining production efficiency.
3Manufacturing precision
If metal strips are welded to form refining bars on back plate, then manufacturing precision improves enabling very dense refining surface configurations, but device complexity increases due to extensive welding work required
Solution Approach 1:
Instead of welding individual metal strips to form refining bars, the refining surface is segmented into pre-formed refining segments. These segments are assembled together using fastening means rather than extensive welding, reducing the complexity of the manufacturing process while maintaining the precision of very dense refining surface configurations.
Solution Approach 2:
Fastening means are used as an intermediary method to attach the pre-formed refining segments to the back plate and to each other. This alternative to direct welding simplifies the manufacturing process while still achieving the required precision for very dense refining surface configurations.
4Manufacturing precision
If metal strips are welded to form refining bars on back plate, then manufacturing precision improves, but loss of time increases due to extensive welding work
Solution Approach 1:
The refining surface is divided into pre-formed segments that can be manufactured separately with precise dimensions. These segments are then assembled using fastening means rather than extensive welding, significantly reducing the time required for manufacturing while maintaining the precision of very dense refining surface configurations.
Solution Approach 2:
The refining segments are pre-formed with precise configurations before assembly. This preliminary manufacturing of segments allows for quality control and reduces the time required for final assembly, as the complex precision work has already been done on individual segments rather than requiring extensive welding during assembly.
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 approach efficiently manufactures refining segments with very dense surface configurations, reducing manufacturing costs and time, while ensuring complete and smooth bonding of refining bars, thus improving the refining process's effectiveness and durability.
Implementation Method 1
by applying at least one solidifying substance between the at least one refining bar element and the back plate
Data Source
AI summary
A refining segment (4, 8) for refining fibrous material, and a refining segment (4, 8) for a refiner (1) for refining fibrous material is formed by arranging at least one set of profiled wires (22) next to each other and substantially immovable with respect to each other, wherein a width (Wa) of a bottom (22a) of the profiled wire (22) is different from a width (Wb) of a top (22b) of the profiled wire (22), to form at least one refining bar element (24), and fastening the at least one refining bar element (24) onto a back plate (19), wherein said back plate forms a body of the refining segment (4, 8), by applying at least one solidifying substance (25) between the at least one refining bar element (24) and the back plate (19).