Segmented Disk Cutter for Lower-Force Rock Breakout

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Solution Overview

Problem

Existing cutting assemblies require substantial cutting forces to cut through rock formations, and they are not suitable for confined spaces like subterranean mines.

Innovation Solution

A disk cutter design with multiple sets of tool holders and cutting elements arranged in a predetermined sequence, featuring polycrystalline diamond compacts, which reduces cutting forces and allows versatile operation in both horizontal and vertical orientations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If traditional cutting assemblies with cylindrical cutting elements are used, then cutting capability is achieved, but substantial cutting forces are required

Engineering Contradiction:

Improvecutting forcesVSAvoidcutting efficiency

Core Design Contradiction:

ForceVSProductivity

Solution Approach 1:

The cutting assembly is segmented into multiple sets of tool holders and cutting elements arranged in a predetermined sequence around the cutter body. Each set contains multiple cutting elements positioned at different angular locations, creating multiple cutting zones that distribute the cutting load and reduce peak cutting forces while maintaining effective rock cutting capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different cutting elements are positioned at specific angular locations around the cutter body to create optimized cutting zones. The predetermined sequence of configurations ensures that cutting elements are strategically placed to distribute cutting forces locally across multiple zones, reducing the substantial forces required by traditional single-zone cutting assemblies

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If equipment is designed for above ground quarry operations, then large rock slabs can be extracted, but the equipment is not suitable for confined subterranean mine spaces

Engineering Contradiction:

Improveoperational versatilityVSAvoidequipment size

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The disk cutter assembly is designed with a compact circular configuration that can operate in multiple orientations and environments. The same cutting assembly can be deployed both above ground in quarries for extracting large rock slabs and below ground in confined mine spaces, eliminating the need for separate equipment designs for different operational contexts

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The cutting elements are arranged in a circular pattern around the cutter body, allowing the assembly to cut rock formations from multiple angular positions in a single rotation. This circular arrangement enables the equipment to adapt to different spatial constraints and operate effectively in both open quarry environments and confined subterranean spaces

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20250320817A1Disk cutter

Publication Date: 2025.10.16 ELEMENT SIX (UK) LTD

AI summary

This disclosure relates to a disk cutter comprising a cutter body, a plurality of tool holders and a plurality of cutting elements mounted to the tool holders. The tool holders and cutting elements are provided in at least one set about the cutter body, each set comprising two or more tool holders and two or more cutting elements arranged in a pre-determined sequence of configurations.