Burr Removal Device Using Suction-Accelerated Abrasive Grains
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Solution Overview
Problem
Existing burr removal methods for electronic components, such as wet barrel polishing and air blast apparatus, face challenges like excessive polishing, dimensional inaccuracies, workpiece damage, and high manufacturing costs, as well as scattering and cracking issues due to high-pressure gas-solid flows.
Innovation Solution
A burr removal method and device utilizing a processing container with a suction mechanism to accelerate abrasive grains to a predetermined speed using air flow, allowing them to contact and remove burrs from objects without excessive cutting, while recovering the abrasive grains to prevent scattering, and using a fluidized state to uniformly distribute and stir the objects for effective deburring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If wet barrel polishing method is used to remove burrs, then polishing ability is improved, but dimensional accuracy deteriorates due to excessive polishing
Solution Approach 1:
The patent changes the fundamental parameter of the polishing method from wet barrel polishing to air blast polishing. This involves changing the medium from liquid slurry to compressed air, changing the polishing mechanism from mechanical friction to pneumatic impact, thereby achieving effective burr removal while preventing excessive polishing that compromises dimensional accuracy
2Power
If wet barrel polishing method is used to remove burrs, then polishing ability is improved, but manufacturing cost increases due to wastewater processing and drying requirements
Solution Approach 1:
The patent replaces the wet mechanical polishing system with a dry pneumatic system. By substituting liquid-based wet barrel polishing with air blast polishing using compressed air, the method eliminates the need for wastewater treatment facilities and drying equipment, thereby reducing manufacturing costs while maintaining effective burr removal capability
Solution Approach 2:
The patent utilizes pneumatic principles by employing compressed air to accelerate abrasive particles and impact burrs. The air blast apparatus uses high-velocity air flow to carry abrasive grains that strike and remove burrs, providing an effective alternative to liquid-based polishing methods and eliminating associated waste handling costs
3Power
If air blast apparatus with high pressure compressed air is used, then polishing power is improved, but workpiece stability deteriorates causing scattering
Solution Approach 1:
The patent applies local quality by directing the air blast and abrasive particles precisely at the burr locations rather than uniformly across the entire workpiece surface. This localized application of high-velocity particles removes burrs while leaving the main body of the workpiece undisturbed, preventing scattering and maintaining workpiece stability
Solution Approach 2:
The patent uses partial action by applying the high-velocity air blast only to the extent necessary for burr removal. The compressed air and abrasive particles are directed specifically at burr regions rather than the entire workpiece, providing sufficient polishing power where needed while avoiding excessive action that would cause workpiece scattering
4Power
If air blast apparatus with high pressure compressed air is used, then polishing power is improved, but reliability deteriorates causing cracking and chipping
Solution Approach 1:
The patent changes the pressure parameter of the air blast to an optimized range that provides sufficient polishing power for burr removal while remaining below the threshold that would cause cracking or chipping. By carefully controlling the compressed air pressure and abrasive particle velocity, the method achieves effective deburring while preserving workpiece integrity and reliability
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 method effectively removes burrs from electronic components without damaging them, reduces manufacturing costs, and prevents abrasive grain scattering, ensuring precise deburring and improved dimensional accuracy.
Implementation Method 1
a suction mechanism which generates air flow in a direction from the abrasive grain feed mechanism to the processing container by suction force
Implementation Method 2
a suction mechanism which generates air flow in a direction from the abrasive grain feed mechanism to the processing container by suction force
Implementation Method 3
allowing the abrasive grains to contact or collide with the plurality of objects to be processed, to thereby remove burrs
Implementation Method 4
allowing the abrasive grains to contact or collide with the plurality of objects to be processed, to thereby remove burrs
Implementation Method 5
a stirring mechanism which stirs the plurality of objects to be processed set in the processing container
Data Source
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AI summary
A burr removal method includes: a step of preparing a burr removal device including a processing container and a suction mechanism for generating suction force, and a plurality of objects to be processed; a step of setting the plurality of objects to be processed in the processing container; a step of stirring the plurality of objects to be processed which are set in the processing container; and a step of removing burrs from the plurality of objects to be processed in such a manner that abrasive grains, fed to the plurality of objects to be processed in the stirred state, are accelerated to a predetermined speed by air flow generated by operating the suction mechanism, to thereby contact or collide with the plurality of objects to be processed.