Traversing Grinding Wheel for Uniform Rubber Belt Resurfacing
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Solution Overview
Problem
Conventional grinding methods for resurfacing rubber belts and rollers in the sanforizing process are inefficient, leading to uneven scales, high energy consumption, labor costs, and extensive downtime, with issues like rubber reversion and hazardous talcum powder usage.
Innovation Solution
A grinding apparatus with a small steel grinding wheel coated with tungsten carbide grit that traverses a track, allowing for precise resurfacing on the production line, reducing downtime and energy consumption, and utilizing an automated system with efficient dust collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large grinding roller is used to resurface the rubber belt, then the entire width of the belt can be ground at once, but the belt surface bounces away from the roller producing horizontal chatter marks and uneven scale
Solution Approach 1:
The patent divides the grinding operation into multiple passes using a smaller grinding wheel that traverses the belt width rather than using one large roller to cover the entire width at once. This segmentation allows better control of the grinding contact and eliminates the bouncing effect that causes chatter marks.
Solution Approach 2:
The patent introduces a traversal dimension by moving the grinding wheel across the belt width in addition to the rotational grinding action. This transforms the grinding process from a single-point contact rotation to a two-dimensional scanning motion, ensuring uniform scale across the entire belt surface.
2Ease of operation
If an abrasive grinding roller is used to resurface the rubber belt, then the belt can be ground on-line, but the roller requires a 15-25 hp electric motor increasing energy costs and generates excessive heat causing rubber reversion
Solution Approach 1:
The patent changes the material parameter of the grinding wheel from conventional abrasive materials to diamond-coated wheels, which have higher cutting efficiency and generate less heat. This parameter change allows effective grinding with lower motor power, reducing energy consumption while maintaining on-line capability.
Solution Approach 2:
The patent converts the previously harmful effect of heat generation into a benefit by using diamond-coated wheels that resist heat buildup, preventing rubber reversion while maintaining the on-line grinding advantage.
3Ease of manufacture
If talcum powder is used as solid lubricant during grinding, then the resurfacing process can be lubricated, but the powder spreads over large areas creating workplace hazards and requiring extensive cleanup
Solution Approach 1:
The patent eliminates the need for talcum powder lubricant by using diamond-coated wheels that require no external lubrication, thereby discarding the harmful lubricant substance entirely and avoiding all associated cleanup and contamination issues.
4Manufacturing precision
If conventional off-line stationary lathes are used to resurface the rubber belt, then the belt can be ground, but the heavy belt must be removed from the production line requiring personnel to move products weighing over a ton
Solution Approach 1:
Instead of removing the heavy belt from the production line to a stationary lathe, the patent inverts the approach by bringing a compact diamond-coated grinding wheel to the belt on the production line, enabling on-line resurfacing and eliminating production downtime.
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 solution provides a uniform scale, reduces downtime and labor costs, minimizes cleanup, and extends the operational life of the grinding wheel, enabling faster and more efficient resurfacing with minimal environmental impact.
Implementation Method 1
A grinding apparatus with a small steel grinding wheel coated with tungsten carbide grit that traverses a track, allowing for precise resurfacing
Data Source
AI summary
The present invention provides an apparatus for resurfacing a rotating elastomer substrate. The apparatus utilizes a motorized grinding wheel, said motorized grinding wheel rotating in a direction counter to the rotating elastomer substrate and having an axis of rotation parallel to the axis of rotation of the rotating elastomer substrate, wherein the perpendicular distance between the motorized grinding wheel and the rotating elastomer substrate is adjustable so as to control the amount of elastomer substrate that is removed; and a mount for said motorized grinding wheel, wherein said mount is located proximal to the rotating elastomer substrate that comprises a part of a production line and wherein the mount is capable of traversing parallel to the rotating elastomer substrate.