Saw Disk Planarization Machine With Sensor-Guided Hammer Correction
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Solution Overview
Problem
The production of circular saw disks requires manual handling and processing to ensure planarity, which is time-consuming, operator-dependent, and poses safety risks due to the weight and size of the disks, leading to inefficiencies and increased costs.
Innovation Solution
A machine tool with a spindle unit, capacitive sensor assembly, and hammer assembly that automatically detects and corrects planarity discrepancies on saw disks by 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 ensure planarity, then planarity precision can be maintained within tolerances, but processing time increases and operator dependency increases
Solution Approach 1:
The patent replaces the manual mechanical system with an automated system comprising a sensor assembly that optically detects planarity deviations and a hammer assembly that automatically strikes corrective areas. The processor controls the hammer assembly based on sensor data, eliminating manual intervention while maintaining planarity precision within tolerances and significantly improving processing speed.
Solution Approach 2:
The machine tool performs self-correction by using the sensor assembly to detect planarity issues and the hammer assembly to automatically strike the necessary corrective blows without operator intervention. The system serves itself by autonomously identifying and correcting deviations, reducing both processing time and operator dependency while maintaining precision.
2Manufacturing precision
If manual hammering is used to correct planarity deviations, then corrective force can be applied precisely, but operator skill dependency increases and processing becomes slower
Solution Approach 1:
The sensor assembly continuously monitors planarity deviations and provides feedback to the processor. The processor then controls the hammer assembly to strike corrective areas with precise force and positioning. This closed-loop feedback system eliminates the need for operator skill while maintaining high correction precision, as the system automatically adjusts based on real-time sensor data.
3Adaptability or versatility
If larger and heavier disks are processed, then market demands are met, but safety risks increase and handling difficulty increases
Solution Approach 1:
The patent replaces manual handling and processing with an automated system where the sensor assembly scans the disk surface and the hammer assembly applies corrective forces. This automation eliminates the need for operators to physically handle large, heavy disks, thereby maintaining the ability to process oversized disks while significantly reducing safety risks and handling difficulties.
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, efficient, and safe automatic planarization of saw disks, reducing operator intervention and processing time while maintaining tolerance standards, and can handle larger and heavier disks with improved safety and reduced costs.
Implementation Method 1
a sensor assembly (4) comprising at least one carriage (11) for handling at least one sensor (10) for measuring planarity differences
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The present invention is part of machine tools that today are widely used in all mechanical workshops, often being designed and built also to perform very specific tasks. In particular, the present invention relates to the processing of discs for circular saws or saw-disks.