Saw Disk Planarity Correction Using Sensor-Guided Hammering
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Solution Overview
Problem
The production of circular saw disks requires manual processing to maintain planarity, which is time-consuming, operator-dependent, and poses safety risks due to the handling of increasingly heavy and large disks, with existing automated solutions unable to fully delegate the manufacturing process.
Innovation Solution
A machine tool with a spindle unit, capacitive sensor assembly, and hammer assembly that automatically measures and corrects planarity discrepancies on saw disks, using a database to determine the necessary force and number of hammer blows for precise and repeatable planarization, allowing for self-learning and autonomous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual processing is used to maintain planarity, then planarity precision can be achieved within tolerance limits, but processing time increases and operator safety risks increase
Solution Approach 1:
The patent replaces manual mechanical processing with an automated system comprising a sensor assembly for detecting planarity deviations and a hammer assembly for automatic correction. The sensor assembly measures surface deviations while the hammer assembly delivers controlled blows to correct them, eliminating manual intervention while maintaining precision and reducing processing time.
Solution Approach 2:
The system enables self-service processing where the machine automatically detects and corrects planarity deviations without operator intervention. The control unit coordinates the sensor and hammer assemblies to autonomously perform measurement and correction cycles, making the process independent of manual operation while maintaining high precision.
2Manufacturing precision
If manual processing is used to maintain planarity, then planarity precision can be achieved within tolerance limits, but operator safety risks increase due to handling heavy disks
Solution Approach 1:
The patent replaces manual mechanical processing with an automated system comprising a sensor assembly for detecting planarity deviations and a hammer assembly for automatic correction. The sensor assembly measures surface deviations while the hammer assembly delivers controlled blows to correct them, eliminating manual intervention while maintaining precision and reducing processing time.
Solution Approach 2:
The system introduces intermediary devices (sensor assembly and hammer assembly) between the operator and the heavy disk. These intermediaries perform the hazardous tasks of measurement and correction, protecting the operator from direct contact with heavy components while ensuring precise planarity control.
3Productivity
If automated processing is implemented, then processing speed and safety improve, but device complexity increases
Solution Approach 1:
The patent segments the automated system into distinct functional modules: a sensor assembly for detection, a hammer assembly for correction, and a control unit for coordination. This segmentation allows each component to perform its specific function independently, simplifying the overall design and maintenance while enabling high-speed automated operation.
Solution Approach 2:
The sensor assembly and hammer assembly are designed as multi-functional units that can handle various disk types and sizes. The control unit coordinates multiple operations (detection, measurement, correction, verification) using the same hardware components, reducing the need for additional specialized equipment and managing device complexity.
4Productivity
If automated processing is implemented, then processing speed and repeatability improve, but manufacturing cost increases
Solution Approach 1:
The patent segments the automated system into distinct functional modules: a sensor assembly for detection, a hammer assembly for correction, and a control unit for coordination. This segmentation allows each component to perform its specific function independently, simplifying the overall design and maintenance while enabling high-speed automated operation.
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
The machine tool enables precise, safe, and efficient planarization of saw disks within tolerance limits, reducing processing time and costs while minimizing operator risk and improving handling of heavy disks through automated and industrially repeatable processes.
Implementation Method 1
a capacitive sensor (10) for measuring planarity differences on at least one face of the saw disk on each part of said face
Data Source
AI summary
A machine tools for processing of a saw disk includes a processor; a spindle unit having a shank provided with a flange to mount the saw disk to be rotated for processing for planarity thereof; sensor assembly having a sensor to be slide from the periphery of said saw disk to the centre thereof, wherein said sensor detects areas of discrepancy in planarity in each part of a disk face of said saw disk and communicating said data to said processor; and a hammer assembly connected to a transverse carriage assembly, the hammer assembly having: a beating head, and a preloading spring with a preload piston coupled to the beating head, wherein the preload piston is configured to load the preloading spring to transfer elastic energy to the beating head for giving, said beating head, the thrust for striking the areas of discrepancy of the saw disk.