Impact cutter blade and holder system and method

An impact cutter blade and holder system is disclosed. The impact cutter blade and holder system includes: a cutter disk, a plurality of impact holders, and a plurality of impact cutter blades. The cutter disk has a central axis about which the cutter disk is configured to rotate. The plurality of impact holders are secured to the cutter disk. The plurality of impact cutter blades is secured to the plurality of impact holders.

TECHNICAL FIELD

The present disclosure generally relates to an Impact Cutter Blade and Holder system and method. More particularly, the present disclosure relates to an Impact Cutter Blade and Holder system and method that reduces maintenance and improves performance by protecting its components from collisions with comminution material.

DESCRIPTION OF THE RELATED ART

There exists a need in many industries to reduce large pieces of solid material to a particulate form. For instance, in managing wood and tree waste, it is desirable to grind stumps, branches, and wood scraps into smaller wood chips. Wood chips are more easily and efficiently transported, stored, and used for a variety of purposes. In other instances, it is desirable to reduce large pieces of waste material, such as plastic, for recycling or disposal. In still other instances, it is desirable to reduce pieces of rock, metal, asphalt, or other extremely hard material, for disposal.

Refiners of various size and operation are generally available for performing this function. One style of refiner includes a refining chamber defined by a sidewall and a bottom floor at one end of the sidewall. An annular ring in the same plane and surrounding the bottom floor is attached to the sidewall and rotates with the sidewall. For instance, a refiner of this style may include a comminuting chamber in which a rotatably-mounted cutter disk with attached blades impacts solid material introduced into the chamber and reduces the material to particulate form.

Some such refiners operate by rotating both the chamber sidewall and the bladed cutter disk, sometimes in the same direction, and sometimes in opposite directions. The rotation of the sidewall imparts rotational motion to the solid material placed in the chamber. As the material in the chamber rotates with the chamber sidewall, the material comes into contact with the rotating cutter disk. The blades of the cutter disk impact the material, thereby ripping and tearing the material into successively smaller pieces. The annular portion of the bottom of the chamber that rotates with the sidewall typically includes a screened exit through which the material, once refined to a particular size, may pass out of the chamber.

The old style blades of the cutter disks were held in place by a “backer” (i.e., a short hardened key stock) and a “keeper” (i.e., a hardened wedge). In prior blade and swing lock holder assemblies, a blade was inserted into a slot of the holder, and then wedged into place. The various components of these traditional cutter disks would become damaged on a regular basis due to the constant collision with the comminution material. When the various components of these traditional cutter disks had to be replaced or repaired due to damage from the comminution material, the maintenance costs were sizeable and the maintenance time periods were protracted.

There is a continuing need in the art for a cutter disk and associated components that are more protected from impact damage caused by the comminution material and contaminates in the material, which results in increased maintenance and reduced performance of the refiner.

Notably, all of the subject matter discussed in this section is not necessarily prior art and should not be assumed to be prior art merely as a result of its discussion in this section. Accordingly, any recognition of problems in the prior art discussed in this section or associated with such subject matter should not be treated as prior art unless expressly stated to be prior art. Instead, the discussion of any subject matter in this section should be treated as part of the identification of the technological problem to be overcome, which in and of itself may also be inventive.

BRIEF SUMMARY

One embodiment of an impact cutter blade and holder system may be summarized as including: a cutter disk having a central axis about which the cutter disk is configured to rotate; a plurality of impact holders, wherein each of the plurality of impact holders is secured to the cutter disk via bolts; a plurality of impact cutter blades, wherein an associated impact cutter blade of the plurality of impact cutter blades is secured to an associated impact holder of the plurality of impact holders; a plurality of wear slugs, wherein an associated wear slug of the plurality of wear slugs is secured to an associated impact holder of the plurality of impact holders, wherein the associated wear slug is shaped, sized, and securely positioned to shield the associated impact holder of the plurality of impact holders from damage by comminution material; a plurality of impact tabs, wherein an associated impact tab of the plurality of impact tabs is secured between an associated impact holder and associated impact cutter blade, wherein the associated impact tab of the plurality of impact tabs is shaped, sized, and securely positioned to shield the associated impact holder from a trailing edge of the associated impact cutter blade, due to collision of the associated impact cutter blade with the comminution material; and a disk wear cover plate secured to the cutter disk, wherein the disk wear cover plate is shaped and sized to shield the cutter disk and the secured plurality of impact holders from damage by comminution material.

Another embodiment of an impact cutter blade and holder system may be summarized as including: a cutter disk having a central axis about which the cutter disk is configured to rotate; a plurality of impact holders, wherein each of the plurality of impact holders is secured to the cutter disk via bolts; a plurality of impact cutter blades, wherein an associated impact cutter blade of the plurality of impact cutter blades is secured to an associated impact holder of the plurality of impact holders; a plurality of wear slugs, wherein an associated wear slug of the plurality of wear slugs is secured to an associated impact holder of the plurality of impact holders, wherein the associated wear slug is shaped, sized, and securely positioned to shield the associated impact holder of the plurality of impact holders from damage by comminution material.

Each of the plurality of impact holders may contain a holder bolt hole for receiving a blade bolt, and a blade mounting slot for receiving a held end of an impact cutter blade. The associated impact holder of the plurality of impact holders may include a push-slug bolt, wherein the push-slug bolt tightens the associated wear slug in place. The associated wear slug is mounted on the leading side of the associated impact holder via a machine fit. The associated impact cutter blade of the plurality of impact cutter blades may have a leading edge positioned to collide with comminution material and a trailing edge opposite the leading edge, the associated impact cutter blade may have a cutter end that is located away from the associated impact holder and a held end that is secured in the associated impact holder. The associated impact cutter blade of the plurality of impact cutter blades may contain a blade bolt hole for securing the associated impact cutter blade to the associated impact holder using the blade bolt hole and a blade bolt.

The associated impact cutter blade of the plurality of impact cutter blades may be secured through the blade bolt hole of the associated impact cutter blade to the associated impact holder using the blade bolt and a stepped nut, wherein the stepped nut may have a lower portion and a stepped portion that is raised higher than the lower portion of the stepped nut, wherein the stepped portion of the stepped nut may contact the impact cutter blade on a trailing edge of the blade bolt hole. The associated impact cutter blade of the plurality of impact cutter blades may include a ridge (e.g., pivot weld) that runs along a length of the associated impact cutter blade and acts as a fulcrum when the associated impact cutter blade is secured in a blade mounting slot of the associated impact holder. When the blade bolt is tightened against the stepped nut, leverage is generated against the fulcrum that forces a leading edge of the associated impact cutter blade against a forward opposite side of the blade mounting slot in the impact holder. This leverage provides tension that keeps the blade bolt from coming loose. Additionally, a hex hole holds the nut so that the blade bolt can be removed with only one wrench.

The associated wear slug of the plurality of wear slugs may be mounted to the leading side of the associated impact holder via a machine fit. The push-slug bolt tightens the associated wear slug in place. The associated wear slug is tapered from its smallest end by the push bolt to its largest end at the machine fit to the associated impact holder. The associated wear slug of the plurality of wear slugs is larger in diameter than the associated impact holder. As such, the associated wear slug presents a larger profile to incoming comminution material than the associated impact holder, and the associated wear slug may protect the associated impact holder by shielding the associated impact holder from collisions with the incoming comminution material that would otherwise damage the associated impact holder. The associated wear slug that is mounted on the associated impact holder may only expose a third of a circumference of the associated wear slug to collision with the comminution material, and the associated wear slug may be rotatable to three separate positions while shielding the associated impact holder, each position representing a third of the circumference of the associated wear slug.

Still another embodiment of an impact cutter blade and holder system may be summarized as including: a cutter disk having a central axis about which the cutter disk is configured to rotate; a plurality of impact holders, wherein each of the plurality of impact holders is secured to the cutter disk via bolts; a plurality of impact cutter blades, wherein an associated impact cutter blade of the plurality of impact cutter blades is secured to an associated impact holder of the plurality of impact holders; and a plurality of impact tabs, wherein an associated impact tab of the plurality of impact tabs is secured between an associated impact holder and associated impact cutter blade, wherein the associated impact tab of the plurality of impact tabs is shaped, sized, and securely positioned to shield the associated impact holder from a trailing edge of the associated impact cutter blade, due to collision of the associated impact cutter blade with the comminution material.

Each of the plurality of impact holders may contain a holder bolt hole for receiving a blade bolt, and a blade mounting slot for receiving a held end of an impact cutter blade. The associated impact holder may further include an impact tab locating notch for locating an associated impact tab, wherein the impact tab locating notch is at substantially wider than the trailing edge of the associated impact cutter blade. The associated impact cutter blade of the plurality of impact cutter blades may have a leading edge positioned to collide with comminution material and a trailing edge opposite the leading edge, the associated impact cutter blade may have a cutter end that is located away from the associated impact holder and a held end that may be secured in the associated impact holder. The associated impact cutter blade of the plurality of impact cutter blades may include an impact tab securing notch on the trailing edge of the associated impact cutter blade.

The associated impact cutter blade of the plurality of impact cutter blades may contain a blade bolt hole for securing the associated impact cutter blade to the associated impact holder using the blade bolt hole and a blade bolt. The associated impact cutter blade of the plurality of impact cutter blades may be secured through the blade bolt hole of the associated impact cutter blade to the associated impact holder using the blade bolt and a stepped nut, wherein the stepped nut may have a lower portion and a stepped portion that is raised higher than the lower portion of the stepped nut, the stepped portion of the stepped nut may contact the impact cutter blade on a trailing edge of the blade bolt hole.

The associated impact cutter blade of the plurality of impact cutter blades may include a ridge (e.g., pivot weld) that runs along a length of the associated impact cutter blade and acts as a fulcrum when the associated impact cutter blade is secured in a blade mounting slot of the associated impact holder. When the blade bolt is tightened against the stepped nut, leverage is generated against the fulcrum that forces a leading edge of the associated impact cutter blade against a forward opposite side of the blade mounting slot in the impact holder. This leverage provides tension that keeps the bolt from coming loose. Additionally, the hex hole holds the nut so that the blade bolt can be removed with only one wrench. The associated impact tab of the plurality of impact tabs may shield the associated impact holder from damage caused by a trailing edge of the associated impact cutter blade when the associated impact cutter blade encounters the comminution material. The associated impact tab may be positioned in an impact tab securing notch in a trailing edge of the associated impact cutter blade, between the associated impact cutter blade and the associated impact holder, and the associated impact tab may be positioned in an impact tab locating notch of the associated impact holder.

A leading end of the associated impact tab may abut the impact tab securing notch in the trailing edge of the associated impact cutter blade, while a trailing end of the associated impact tab may abut the impact tab locating notch of the associated impact holder. The associated impact cutter blade of the plurality of impact cutter blades may have an impact tab securing notch with a 90-degree angle in a trailing edge of the associated impact cutter blade that holds the associated impact tab in place, the 90-degree angle of the impact tab securing notch may enable the associated impact tab to support the associated impact cutter blade against both radial force and tangential forces. The associated impact tab of the plurality of impact tabs may have a larger width than a trailing edge of the associated impact cutter blade, wherein the larger width of the associated impact tab spreads out and diminishes forces transmitted by the associated impact cutter blade towards the associated impact holder due to collision of the associated impact cutter blade with the comminution material.

The associated impact tab of the plurality of impact tabs may be formed from a metallic alloy that is softer than the associated impact holder such that force from the associated impact cutter blade deforms the associated impact tab before the associated impact holder.

Yet another embodiment of an impact cutter blade and holder system may be summarized as including: a cutter disk having a central axis about which the cutter disk is configured to rotate; a plurality of impact holders, wherein each of the plurality of impact holders is secured to the cutter disk via bolts; a plurality of impact cutter blades, wherein an associated impact cutter blade of the plurality of impact cutter blades is secured to an associated impact holder of the plurality of impact holders; and a disk wear cover plate secured to the cutter disk, wherein the disk wear cover plate is shaped and sized to shield the cutter disk and the secured plurality of impact holders from damage by comminution material.

The disk wear cover plate may be secured to the cutter disk using plate mounting bolts, and the disk wear cover plate may reduce friction, energy consumption, and fuel consumption since collision against the disk wear cover plate by the comminution material is oblique rather than direct.

In still another embodiment, an impact cutter blade clamping method that employs an impact cutter blade and holder system is disclosed. The impact cutter blade clamping method includes: providing a cutter disk and a plurality of impact holders, wherein the cutter disk has a central axis about which the cutter disk is configured to rotate, and wherein each of the plurality of impact holders is secured to the cutter disk; configuring the plurality of impact holders to include blade mounting slots, wherein each blade mounting slot includes sidewalls and is shaped and sized to receive an impact cutter blade, and wherein the impact cutter blade includes two impact cutter blade sidewalls and a leading edge that is positioned to intersect with comminution material when the cutter disk rotates; positioning a ridge on at least one of an impact cutter blade sidewall or a blade mounting slot sidewall of an associated impact holder of the plurality of impact holders; placing the impact cutter blade in the blade mounting slot of the associated impact holder; clamping, using a blade bolt, the impact cutter blade to the associated impact holder and against the ridge, which acts as a fulcrum that reduces vibration and provides increased rigidity at the leading edge of the impact cutter blade; and generating leverage against the fulcrum that forces the leading edge of the associated impact cutter blade against a forward opposite sidewall of the blade mounting slot in the associated impact holder.

In another aspect of the impact cutter blade clamping method, a blade bolt is tightened against a stepped nut that is positioned opposite of the ridge on at least one of an impact cutter blade sidewall or a blade mounting slot sidewall of an associated impact holder of the plurality of impact holders.

These features with other technological improvements, which will become subsequently apparent, reside in the details of construction and operation as more fully described hereafter and claimed, reference being had to the accompanying drawings forming a part hereof.

DETAILED DESCRIPTION

Persons of ordinary skill in the art will understand that the present disclosure is illustrative only and not in any way limiting. Other embodiments of the presently disclosed system and method readily suggest themselves to such skilled persons having the assistance of this disclosure.

Each of the features and teachings disclosed herein can be utilized separately or in conjunction with other features and teachings to provide an impact cutter blade and holder system and method. Representative examples utilizing many of these additional features and teachings, both separately and in combination, are described in further detail with reference to attachedFIGS. 1-6. This detailed description is merely intended to teach a person of skill in the art further details for practicing aspects of the present teachings and is not intended to limit the scope of the claims. Therefore, combinations of features disclosed above in the detailed description may not be necessary to practice the teachings in the broadest sense, and are instead taught merely to describe particularly representative examples of the present teachings.

In the description below, for purposes of explanation only, specific nomenclature is set forth to provide a thorough understanding of the present system and method. However, it will be apparent to one skilled in the art that these specific details are not required to practice the teachings of the present system and method.

Referring now toFIG. 1, in one embodiment of the present disclosure, the impact cutter blade and holder system is implemented as a refiner, which may be constructed in accordance with the present disclosure.

Alternatively, the impact cutter blade and holder system may also be embodied in a variety of other forms. Typically, a refiner will include a refiner chamber, a cutter disk, an engine that powers the refiner chamber and cutter disk, and a conveyor that carries away the refined material that has exited the refiner chamber.FIG. 1is a perspective side view of one exemplary embodiment of such a refiner.

The refiner10depicted inFIG. 1includes a rotating refiner chamber12and a rotating bladed cutter disk located inside the chamber12. The refiner10includes an engine14that powers the operation of the refiner10. The engine14is typically a diesel engine, but other types of engines, such as a gasoline engine, may be used. Alternatively, or in addition, other power sources, including electric and hydraulic motors, may be used to operate the refiner10. The refiner chamber12and the engine14are mounted on a frame16that preferably has wheels18. The wheels18allow the frame16to be transported from one job site to another. Adjustable jack legs20mounted at an end of the frame16opposite the wheels18may be used to maintain the refiner10in a level position.

In one embodiment, the refiner10further includes a conveyor22that collects and carries away particulate material discharged from the refiner chamber12. The conveyed particulate material may be deposited in a pile on the ground, in the bed of a truck, and the like. Conventional components may be used to construct the conveyor22including belt systems, augers, or other mechanisms capable of conveying the particulate matter from the refiner chamber12. See, e.g., the reciprocating screening conveyor described in U.S. Pat. No. 6,000,554, assigned to the assignee of the present disclosure and incorporated by reference herein.

Referring now toFIGS. 2A-6, the impact cutter blade and holder system and method provides a major technological improvement that reduces operating costs, reduces maintenance, and improves performance. In some embodiments of the impact cutter blade and holder system100, the impact cutter blade and holder system100includes a cutter disk110; a plurality of impact holders130; a plurality of impact cutter blades150, wherein an impact cutter blade150is attached to each impact holder130; a plurality of wear slugs180, wherein a wear slug180is attached to each impact holder130; a plurality of impact tab190, wherein an impact tab190is secured between each impact holder130and associated impact cutter blade150; and a disk wear cover plate200. Notably, the cutter disks110of the impact cutter blade and holder system100may be used in other applications such as attachments for excavators, wheel loaders, tractors, and the like, as well as portable axle or tack mounted stump grinders.

The impact cutter blade and holder system100is retrofitable to most cutter disks manufactured since1990. As shown inFIGS. 2A-2B, the impact holders130of the impact cutter blade and holder system100secure to the cutter disk110in the same way as the traditional “swing lock holders.” However, the impact holders130of the impact cutter blade and holder system100are attached to wear slugs180that provide protection to the impact holders130from comminution material122, e.g., rock, wood (SeeFIG. 1), metal, asphalt, and the like, unlike the traditional “swing lock holders,” which provided no such protection. The impact cutter blades130of the impact cutter blade and holder system100secure to the impact holders130with the assistance of impact tabs190that provide protection to the impact holders130, unlike the traditional “old style blades,” which provided no such protection.

Referring now toFIG. 2A, the cutter disk110of the impact cutter blade and holder system100contains a plurality of through bolt holes112for receiving through bolts114. In one embodiment, the holder mounting bracket is somewhat horseshoe-shaped. Additionally, the cutter disk110of the impact cutter blade and holder system100contains a central axis hole118for receiving a central axle (not shown). Further, the cutter disk110of the impact cutter blade and holder system100contains a plurality of cover plate holes202for securing the disk wear cover plate (described below).

As shown inFIGS. 2A and 2B, each of the plurality of impact holders130of the impact cutter blade and holder system100is connected to the cutter disk110using a through bolt114. Additionally, each impact holder130contains a holder bolt hole132for receiving a blade bolt. A hex nut is used to secure the blade bolt on the underside of the impact holder130. The impact holder130of the impact cutter blade and holder system100also contains a blade mounting slot134for receiving a held end of an impact cutter blade150, as described in further detail below.

Continuing, each impact holder130contains a push-slug bolt136, wherein the push-slug bolt136tightens the associated wear slug180in place, as described in further detail below. The associated wear slug is mounted on the leading side of the associated impact holder via a machine fit. In at least one embodiment, each push-slug bolt136is tightened to 300-350 ft. lbs. of torque. Notably, the push-slug bolt136replaces a push bolt in traditional “swing lock holders” that was only used to reduce circumferential swing.

As shown inFIG. 3A, the impact holder130of the impact cutter blade and holder system100includes a blade removal slot138, through which a lever may be used to remove the impact cutter blade150from the impact holder130. Continuing, the impact holder130includes a front-side contact point140that abuts against the trailing end of the wear slug180. Additionally, the impact holder130of the impact cutter blade and holder system100includes a back-side contact point142which abuts against the leading edge of the impact cutter blade150that is being secured by the impact holder130.

In some embodiments, the impact holder130further includes an impact tab locating notch144for locating an impact tab190, as shown inFIG. 3C-3F. Notably, the impact tab locating notch144is about twice as wide as the trailing edge of the impact cutter blade150to correspond with the width of the impact tab190, which is about twice as wide as the trailing edge of the impact cutter blade150. In another embodiment, the impact tab locating notch144is more than twice as wide as the trailing edge of the impact cutter blade150to correspond with the width of the impact tab190, which is more than twice as wide as the trailing edge of the impact cutter blade150. In another embodiment, the impact tab locating notch144is at least 150% as wide as the trailing edge of the impact cutter blade150to correspond with the width of the impact tab190, which is at least 150% as wide as the trailing edge of the impact cutter blade150. Additionally, since the impact holders130of the impact cutter blade and holder system100are fabricated from thicker plate than the old style holders, the impact holder130of the impact cutter blade and holder system100is stronger, heavier, and more massive than the old style holders.

Referring now toFIGS. 2A, 2B, 3A, and 3B, the plurality of impact cutter blades150in the impact cutter blade and holder system100each have a leading edge152(that collides with the comminution material122) and a trailing edge154(opposite the leading edge152, and away from direction of travel of the cutter disk110). Additionally, each impact cutter blade150in the impact cutter blade and holder system100has a cutter end156(that is positioned to impact with the comminution material122) and a held end158(that is secured in the impact holder130). In some embodiments, the plurality of impact cutter blades150in the impact cutter blade and holder system100each includes an impact tab securing notch160on the trailing edge154. Each of the plurality of impact cutter blades150contains a blade bolt hole162for securing the impact cutter blade150to its associated impact holder130using the holder bolt hole132and a blade bolt.

Referring specifically toFIGS. 3A-3F, in some embodiments of the impact cutter blade and holder system100, each impact cutter blade150contains a fulcrum164(e.g., pivot weld, ridge, or the like) that runs along the length of the impact cutter blade150(from the held end158to the cutter end156). In some embodiments of the impact cutter blade and holder system100that employ a thinner 10 mm impact cutter blade150a, the impact cutter blade150contains a bottom-side ridge166(e.g., pivot weld, or other fulcrum) on the opposite side of the leading edge152of the held end158(as shown inFIG. 3E). This bottom-side ridge166enables one size of impact holder130to work for both a thicker impact cutter blade150b(as shown inFIG. 3D) and the thinner impact cutter blade150a(as shown inFIG. 3E). The bottom-side ridge166provides a contact line that opposes the fulcrum164(e.g., pivot weld, ridge, or the like), while the stepped nut170forces the thinner impact cutter blade150ato compensate for the difference in thickness (from a thicker impact cutter blade150b).

In some embodiments of the impact cutter blade and holder system100, the fulcrum164is located on the impact cutter blade150(i.e., the fulcrum is a raised portion of the impact cutter blade150). In such an embodiment, the fulcrum164(e.g., pivot weld, ridge, or the like) is made of a softer metal than the impact holder130. As such, the fulcrum164(e.g., pivot weld, ridge, or the like) does not damage the impact holder130. The fulcrum164(e.g., pivot weld, ridge, or the like) may be replaced at the same time of every impact cutter blade150change.

Alternatively, in other embodiments of the impact cutter blade and holder system100, the holder fulcrum146(e.g., pivot weld, ridge, or the like) is located on the impact holders130(i.e., the fulcrum is a raised portion inside the impact holder130), as shown inFIG. 3F. The holder fulcrum146is a bottom-facing fulcrum on the top side of the blade mounting slot. Thus, this alternative embodiment employs a fulcrum146(e.g., pivot weld, ridge, or the like) as part of the impact holder130instead of as part of impact cutter blade150. Notably, in this alternative embodiment, the fulcrum146(e.g., pivot weld, ridge, or the like) may become damaged more quickly because the impact cutter blade150is made of a very hard material that would tend to damage a fulcrum146(e.g., pivot weld, ridge, or the like) on the inside of the impact holder130more quickly due to the hardness of the impact cutter blade150. In some embodiments, the impact holder130has a very long life span, while the impact cutter blade150is replaced more frequently since it is absorbing the majority of the damage from the comminution material122. In various embodiments, the impact cutter blades150and impact holders130may be formed by fabrication, casting, forging, forming, and/or any other type of manufacture.

Referring now to another aspect of some embodiments as shown inFIGS. 3A and 3C-3F, the impact cutter blade and holder system100further employs a plurality of stepped nuts170. Each stepped nut170is used to assist in securing an impact cutter blade150to an impact holder130. The stepped nut170has as lower portion and a stepped portion172that is raised higher than the lower portion of the stepped nut170. In some embodiments, the stepped portion172of the stepped nut170abuts the impact cutter blade150on the trailing edge of the blade bolt hole162(i.e., the side of the blade bolt hole162closest to the trailing edge154of the impact cutter blade150, away from the direction of travel of the cutter disk110).

Notably, in such an embodiment, the stepped nut170causes the clamping of the impact cutter blade150in its associated impact holder130. As the blade bolt174is tightened against stepped nut170, leverage is generated against the fulcrum164(e.g., pivot weld, ridge, or the like) which forces the leading edge152of the impact cutter blade150against the forward opposite side of the blade mounting slot134in the impact holder130. This force clamps the impact cutter blade150securely in place and eliminates any possible vibration of the held end158of the impact cutter blade150. Continuing, this force deforms the impact cutter blade150under extreme spring tension. This tension assures that the stepped nut170, the blade bolt174, and the impact cutter blade150do not work loose. This is similar to the effect of a lock washer.

Referring now toFIG. 3B, the leading edge152of the impact cutter blade150is where nearly all of the impact with the comminution material122is received. As such, the point of maximum rigidity is at or in front of the leading edge152of the impact cutter blade150. The leading edge152of the impact cutter blade150lies at or near the extended line of the fulcrum164(e.g., pivot weld, ridge, or the like) and the opposing leading edge to provide the needed strength and rigidity.

As the impact cutter blade150wears, the leading edge152of the impact cutter blade150recedes, but the point of maximum rigidity remains at or in front of the leading edge152of the impact cutter blade150. As the impact cutter blade150slices through the comminution material122, the impact cutter blade150tracks with the comminution material122as long as the point of maximum rigidity remains in front of the extended line of the fulcrum164(e.g., pivot weld, ridge, or the like).

As the blade bolt174and stepped nut170are tightened, the impact cutter blade150is deformed under tension forces to prevent vibration. At the same time, the fulcrum164(e.g., pivot weld, ridge, or the like) and opposing leading side become wedged inside the impact holder130, giving maximum strength to the leading edge152of the impact cutter blade150where it is needed.

In still another aspect of some embodiments, the impact cutter blade and holder system100includes a blade bolt174and a blade washer176. In at least one specific, non-limiting embodiment, the blade bolt174is a Grade 8 fine thread bolt. In some embodiments, the blade bolt174is tightened to about 400-500 ft. lbs. of torque. In some embodiments, the blade washer176is a Grade 8 SAE washer. Notably, the impact cutter blade and holder system100does not require the use of a lock washer on the blade bolt174, since the stepped nut170is held by the hex hole provided, and blade tension holds the blade bolt174and impact cutter blade150in place.

In some embodiments of the impact cutter blade and holder system100, each impact cutter blade150is held in place with a single bolt (e.g., the blade bolt174) and a single nut (i.e., the stepped nut170). In other embodiments, more than one set of blade bolts174, blade bolt holes162, and stepped nuts170are used to fasten a single impact cutter blade150to a single impact holder130.

In one specific, non-limiting embodiment, the blade bolt174is a 1.0 inch×2.5 inches Grade 8 hex cap screw NF (national fine thread). This Grade 8 hex cap screw is a medium carbon alloy tempered steel bolt that is used where hardness and high strength are desired. In another aspect of a specific, non-limiting embodiment, the blade washer176is a 1.0 inch SAE (Society of Automotive Engineers) flat washer. In still another aspect of a specific, non-limiting embodiment, the stepped nut170is a 1.0 inch NF hardened high nut with one end shaved away so that only one side portion presses against the impact cutter blade150.

In some embodiments of the impact cutter blade and holder system100, the stepped nut170is held from turning by the hex hole so the blade bolt174can be removed with only one wrench. The side of the impact holder130fits the hex shape of the stepped nut170and prevents the stepped nut170from turning. Notably, battery powered impact wrenches are now available with enough power to remove and install the blade bolts174, making the change of the impact cutter blade150very efficient.

Referring now toFIGS. 4A-4K, the impact cutter blades150are available in a variety of shapes and sizes. Specifically, in various embodiments of the impact cutter blade and holder system100, many different styles of cutter ends156are employed on various implementations of impact cutter blades150depending on the nature and properties of the comminution material122that is expected to be encountered. The cutter end156of the impact cutter blades150may be long or short, dull or sharp, depending on the material to be cut.

FIG. 4Aillustrates an impact cutter blade150(impact super hardwood) having a cutter end156that is the shortest and strongest blade depicted, and is configured for very hard wood, frozen wood and contaminates such as rock and steel.FIG. 4Billustrates an impact cutter blade150(impact hardwood) having a cutter end156that is the second strongest blade depicted, and is configured for hardwoods and lesser contaminates.FIG. 4Cillustrates an impact cutter blade150(impact softwood) having a cutter end156that is the third strongest blade depicted, and is configured for softwoods and lesser contaminates.FIG. 4Dillustrates an impact cutter blade150(impact ripper) having a cutter end156that is the fourth strongest blade depicted, and is configured for high production in softer, lighter materials.FIG. 4Eillustrates an impact cutter blade150(impact long ripper) having a cutter end156that is the fifth strongest blade depicted, and is configured for very high production in lighter materials.FIG. 4Fillustrates an impact cutter blade150(impact raker) having a cutter end156that is very long, and is configured for clearing grates and higher production.

FIG. 4Gillustrates an impact cutter blade150(impact slicer) having a cutter end156that is very long with a knife edge, and is configured for higher production in fibrous materials.FIG. 4Hillustrates an impact cutter blade150(impact tbc-chipper) having a cutter end156that is a very aggressive blade with a knife edge, and is configured for higher production in fibrous materials when less blade strength is required.FIG. 4Iillustrates an impact cutter blade150(knife edge) having a cutter end156that has a sharp leading edge, and is configured for fibrous materials.FIG. 4Jillustrates an impact cutter blade150(chisel point) having a cutter end156that has a sharp chisel point, and is configured for fiberglass and dense plastics.FIG. 4Killustrates an impact cutter blade150(club) having a cutter end156that has massive hardfacing, and is configured for asphalt shingles.

In some embodiments of the impact cutter blade and holder system100, the impact cutter blades150are more massive than previous swing blades in at least two ways. First, the impact cutter blades150of the impact cutter blade and holder system100are thicker than previous swing blades (0.5 inches for the impact cutter blade150compared to 0.375 inches for the previous swing blades).

Second, the impact cutter blades150of the impact cutter blade and holder system100are wider at the cutter end156(where they extend out of the impact holder130). In one embodiment, the width at the cutter end156of the impact cutter blade150is 3.25 inches (compared to 2.5 inches for the previous swing blades). The strength of the impact cutter blade150to resist breakage at the cutter end156of the impact cutter blade150(i.e., the point at which the impact cutter blade150extends from the impact holder130) is relative to the width times the square of the thickness (i.e., for the old style blades the strength is 2.5×0.375×0.375=0.352; for the new impact cutter blade150the strength is 3.25×0.5×0.5=0.8125). In some embodiments, the metallic alloy employed for the impact cutter blade150possesses about 220,000 psi (tensile strength). Accordingly, the impact cutter blade150is more than twice as strong as previous swing lock blades.

Referring now toFIGS. 2A, 2B, 3A, 3C, and 5, in another aspect of some embodiments, the impact cutter blade and holder system100includes a plurality of wear-absorbing components called wear slugs180on the leading side of each impact holder130. The wear slug180is larger than the impact holder130in diameter and, thus, in the profile that is presented to incoming comminution material122. Accordingly, the wear slug180absorbs most of the wear that the impact holder130would otherwise receive from collision with the comminution material122.

Specifically, the wear slug180has a profile that is larger than the profile of the impact holder130(with respect to its contact with the comminution material122that can cause wear). In this regard, the comminution material122advances toward the circumference of the cutter disk110while the cutter disk110revolves at a high speed. The impact holder130is in the “shadow” of the wear slug180so that the surfaces of the impact holder130only have minimal contact with the comminution material122, while the wear slug180takes the full impact of the comminution material122that is encountered. In one embodiment, the wear slug180is 4.5 inches in diameter, while the holder profile is 4.0 inches in diameter. Thus, the wear slug180extends 0.25 inches further toward the comminution material122than the impact holder130in all directions. The typical advance of the comminution material122towards the impact holder130(in the direction of travel) is about 0.197 inches (which is less than the 0.25 inches that the wear slug180extends beyond the impact holder130).

In some embodiments, the wear slug180can be turned (rotated) to three positions (each position representing a third of the wear slug's circumference) before the wear slug180becomes worn out. The wear slug180is easily removed from the impact holder130and cutter disk110by loosening the push-slug bolt136, and can be rehardfaced and reused. This dramatically reduces the amount and difficulty of maintenance required for the impact holder130, since the wear slug180is absorbing the vast amount of the damage which would previously have been imparted onto the impact holder130.

In one embodiment, the wear slug180is turned by loosening the push-slug bolt136with a 1.5 inches end wrench. The wear slug180is then turned manually and the push-slug bolt136is re-tightened. This configuration and adaptability enable a new wear surface of the wear slug180to be presented to the direction of travel three times before the wear slug180must be replaced.

Referring now toFIG. 5, in one specific, non-limiting embodiment, the outer diameter182of the wear slug180is 4.5 inches, and the inner diameter184of the wear slug180that mounts over the push-slug bolt136is 1.0 inches. In this specific, non-limiting embodiment, the leading edge186of the wear slug180is 3.5 inches and the trailing edge188of the wear slug180is countersunk twice. In this embodiment, the first countersink is 0.25 inches deep and has a 4.0 inches diameter, and the second countersink is an additional 0.25 inches deep and has a 3.5 inches diameter. Notably, these countersinks provide the technological improvement of assisting with the mount and center of the wear slug180on the leading end of the impact holder130(i.e., the end of the impact holder130in the direction of travel).

As described above, the outer diameter182of the wear slug180extends beyond the impact holder130to protect the impact holder130from comminution material122as the wear slug180, impact cutter blade150, and impact holder130rotate in the direction of travel of the cutter disk110into the comminution material122. Thus, the impact holder130travels in the shadow of the wear slug180and is protected from the majority of the impact with the comminution material122. Accordingly, the outer portion of the wear slug180(which is furthest from the central axis hole of the wear slug) receives the vast majority of the impact with the comminution material122to about one third of the wear slug180. Thus, the wear slug180may be rotated on the push-slug bolt136into three approximate positions (i.e., thirds of the wear slug circumference) before the wear slug180needs to be replaced or resurfaced.

In some embodiments, the wear slug180is made using a CNC (computer numerical control) lathe machine. Notably, the wear slug180may be made from mild steel and hard-faced, since a rough finish is acceptable for the use of the wear slug180. Hard-facing is a metalworking process where harder or tougher material is applied to a base metal to harden and toughen the surface of the base material.

Referring now toFIGS. 2A, 2B, 3A, and 3C-3F, in another aspect of some embodiments, the impact cutter blade and holder system100includes a plurality of impact tabs190. In such embodiments, the impact cutter blade and holder system100incorporate a plurality of impact tabs190that protects the impact holders130from excessive damage caused by the trailing edge154of the impact cutter blades150when encountering comminution material122(e.g., large pieces of metal). In previous systems, the impact of comminution material122could swing (rotate) the impact cutter blade150and cause damage to the portion of the blade mounting slot134of the impact holder130that abuts with the trailing edge154of the impact cutter blade150. Specifically, in previous systems the impact of the comminution material122with the leading edge152of the impact cutter blade150caused the impact cutter blade150to swing back in the opposite direction of the rotational travel of cutter disk110and damage an old style holder.

The impact tab190has a leading end192and a trailing end194(opposite the leading end192, away from direction of travel). The impact tab190is positioned in an impact tab securing notch160in the trailing edge154of the impact cutter blade150, between the impact cutter blade150and the impact holder130. The impact tab190is positioned in an impact tab locating notch144of the impact holder130. Thus, the leading end192of the impact tab190abuts the impact tab securing notch160in the trailing edge154of the impact cutter blade150, while the trailing end194of the impact tab190abuts the impact tab locating notch144of the impact holder130.

As shown inFIGS. 3A and 3C-3F, in the impact cutter blade and holder system100, the trailing edge154of the impact cutter blade150is supported by the impact tab190. Specifically, the impact cutter blade150has an impact tab securing notch160in its trailing edge154that holds the impact tab190in place. The 90-degree angle of this impact tab securing notch160enables the impact tab190to support the impact cutter blade150against both radial force and tangential forces generated by impact of the impact cutter blade150with the comminution material122(which impacts the impact cutter blade150at many different angles).

Impact tab locating notch144of the impact holder130, which is where the impact tab190fits into the impact holder130, is wider than the blade mounting slot134in the impact holder130for receiving the impact bade150. The back of the impact tab locating notch144of the impact holder130serves to support the impact component that is pushing the trailing edge of the impact bade150back into the impact holder130. With the impact tab190taking both components of the impact, the blade bolt174is protected from these forces. However, if the impact tab190is not employed, the blade bolt174will receive all of these forces, and will have to be more robust to handle these forces.

In one embodiment, the impact tab190is placed in the impact tab securing notch160in the trailing edge154of impact cutter blade150when the impact cutter blade150is inserted into the impact holder130. Specifically, the impact tab190is positioned in an impact tab locating notch144of the impact holder130. As the impact force (of the impact cutter blade150against the comminution material122) swings the impact cutter blade150back in the opposite direction of the cutter disk's rotational travel about its central axis hole118, the impact tab190is pinched between the trailing edge154of impact cutter blade150and the bearing surface (i.e., the impact tab locating notch144) in the blade mounting slot134of the impact holder130.

The impact tab locating notch144engages the impact tab190to prevent the force of the impact (of the impact cutter blade150against the comminution material122) from pushing the trailing edge154of impact cutter blade150into the blade mounting slot134of the impact holder130. This force is countered by the impact tab locating notch144inside the blade mounting slot134of the impact holder130that bears against the impact tab190. Additionally, the 90-degree angle of this impact tab securing notch160(FIG. 3A) enables the impact tab190to support the impact cutter blade150against additional forces (radial, normal, tangential, and the like) generated by impact of the impact cutter blade150with the comminution material122, which drive inward along the trailing edge154of impact cutter blade150.

In some embodiments, the impact tab190is a small piece of a metallic alloy that can be replaced when the impact cutter blade150is changed. Notably, the impact tab190can be reused if it is not damaged. A technological improvement of the impact cutter blade and holder system100is that the impact tab190protects the blade mounting slot134of the impact holder130from damage from the trailing edge154of the impact cutter blade150due to collision with comminution material122.

In some embodiments, the impact tab190is formed from the same metallic alloy as the impact cutter blade150. In other embodiments, the impact tab190is formed from a metallic alloy that is slightly softer than the impact holder130, thus resulting in the impact tab190deforming before the impact holder130(or impact cutter blade150), which is desirable since the impact tab190is easier (and more cost efficient) to replace. Accordingly, the easily replaceable impact tab190is constructed to be damaged instead of the blade mounting slot134of the impact holder130.

In some embodiments, the impact tab190is twice as wide as the trailing edge154of the impact cutter blade150. The impact tab190protects the impact holder130from being damaged/deformed by the trailing edge154of the impact cutter blade150, since the trailing edge154of the impact cutter blade150is driven towards the impact holder130by collision with the comminution material122. The extended width of the impact tab190(compared to the trailing edge154of the impact cutter blade150) spreads out (and thereby diminishes) the force of the trailing edge154of the impact cutter blade150towards the impact holder130by collision with the comminution material122.

Notably, since the impact tab190presents twice as much surface area to the bearing surface (impact tab locating notch144) of the impact holder130as the trailing edge154of the impact cutter blade150, the impact cutter blade150forcibly abuts against the impact tab190. The doubled surface area of the impact tab190against the blade mounting slot134of the impact holder130reduces the impacting force by half. Therefore, the impact tab190becomes deformed instead of the blade mounting slot134of the impact holder130.

Referring now toFIG. 6, in another aspect of some embodiments, the impact cutter blade and holder system100includes disk wear cover plate200. In one embodiment, the disk wear cover plate200is formed from a metallic alloy that covers the entire top surface of the cutter disk110and the impact holders130. The disk wear cover plate200is mounted to the cutter disk110using the cover plate holes202(shown inFIG. 1) and plate mounting bolts204that align with cover plate holes202in the cutter disk110. In one embodiment, the plate mounting bolts204are tightened to 400-500 ft. lbs. of torque. The disk wear cover plate200has an upper surface206(away from the cutter disk110) that comes into contact with comminution material122. Additionally, the disk wear cover plate200has a lower surface (not shown) facing the cutter disk110that does not come into contact with comminution material122. Notably, the disk wear cover plate200has a smooth surface. Furthermore, the disk wear cover plate200does not require the strength levels of the other parts described herein since contact/collision of the disk wear cover plate200with the comminution material122tends to be tangential rather than direct.

Since the disk wear cover plate200does not receive as much impact (with the comminution material122) as the impact holders130and impact cutter blade150, in some embodiments the disk wear cover plate200is made of a wear-resistant alloy that is harder (but not as high strength as the cutter blade110. This type of wear-resistant alloy is less expensive than the high strength alloys (of which the cutter disk110, impact holders130, and impact cutter blades150are typically made), thus, making the disk wear cover plate200more practical as a replaceable part.

A significant, unexpected technological benefit of the disk wear cover plate200is that its upper surface206is much flatter and smoother than the bare cutter disk110. This flat, smooth surface of the disk wear cover plate200drastically reduces friction, energy consumption (e.g., horsepower requirements), and fuel burn since contact/collision of the disk wear cover disk200with the comminution material122is oblique rather than direct. Without the implementation of the disk wear cover plate200, the top surface of the cutter disk110and the top side of the impact holders130had to be regularly repaired due to damage from impact with comminution material122. In some embodiments, the disk wear cover plate200is removable and can be rehardfaced and reused. Notably, the disk wear cover plate200almost completely eliminates the hardfacing maintenance of the cutter disk110and the top side of the impact holders130.

Another implementation of an impact cutter blade and holder system100is intended mostly for smaller machines that are operated in materials that have low abrasive content. In this implementation, the impact holders are formed as part of the cutter disk by welding (or otherwise securing) holder blocks to produce a one-piece cutter disk. The “holder blocks” have all the features of an impact holder to secure an associated impact cutter blade. In some embodiments, the holder blocks are welded to the cutter disk at various angles then hardfaced to produce finished holder blocks.

In at least one implementation, the one-piece cutter disk is made by welding the holder blocks into a solid cutter disk at various angles. The one-piece cutter disk provides a technological improvement of increased production efficiency. However, the one-piece cutter disk typically must be removed from the refiner for hardfacing maintenance, instead of only removing the impact holders, wear plates, and wear slugs. In some embodiments, the one-piece cutter disk is held in place with a wing nut. Tree service companies are an example where the comminution material122(e.g., stumps chunks and tree limbs) is relatively free of harder contaminates. In this tree service implementation, the one-piece cutter disk may only need maintenance after months of service, whereas in a garbage service implementation, maintenance may be required on a weekly or even daily basis due to the prevalence of harder contaminates and comminution material122.

In still other alternate embodiments of the impact cutter blade and holder system100, the shape of the impact cutter blades150are modified, but the manner in which the impact cutter blades150are clamped to reduce vibration and provide maximum rigidity at the leading edge152or cutting point is maintained. The following embodiments describe several approaches by which the impact cutter blades150and impact holders130can be produced that provide the technological improvements associated with clamping to reduce vibration and provide maximum rigidity at the leading edge152of the impact cutter blades150.

In a first alternate embodiment of impact cutter blade and holder system100, the blade bolt hole162through the impact cutter blade150is moved closer to the trailing edge154. This movement of the blade bolt hole162closer to the trailing edge154of the impact cutter blade150enables a nut to be employed for securing the blade bolt174which provides the proper clamping without the need for the nut to be a stepped nut. However, this configuration with the blade bolt hole162moved closer to the trailing edge154of the impact cutter blade150would not be as strong since the blade bolt174must be smaller in this location (due to space limitations).

In a second alternate embodiment of impact cutter blade and holder system100, each impact cutter blade150includes two blade bolt holes162which are secured with corresponding stepped nuts172to generate proper clamping, which reduces vibration and provides maximum rigidity at the leading edge152of the impact cutter blades150. In still another implementation, the two blade bolt holes162are positioned closer to the trailing edge154of the impact cutter blades150(as described above in the first alternate embodiment) and provide the proper clamping without stepped nuts.

In a third alternate embodiment of impact cutter blade and holder system100, the holder fulcrum146(e.g., pivot ridge) is located in the blade mounting slot134of the impact holders130(instead of on the impact cutter blade150). The holder fulcrum146is a bottom-facing fulcrum on the top side of the blade mounting slot134. This alternate embodiment may also include an opposite side contact fulcrum or pivot ridge166on the impact cutter blade150as shown on the thin impact cutter blade150ainFIG. 3E. In another embodiment, the pivot ridge166is a replaceable pin-like shape that is separate from the impact holder130and the impact cutter blade150. In still another implementation, the pivot ridge166is a piece of key stock that is position in a groove of the impact holder130and/or the impact cutter blade150.

In a fourth alternate embodiment of impact cutter blade and holder system100, the impact cutter blade150does not have a blade bolt hole162in it. Rather, the clamping force is provided by a bolt that is threaded into the impact holder130, with the point of the threaded bolt transmitting pressure at a correct spot. In still another implementation, the impact cutter blade150has a small hole (or at least an indentation) into which the threaded bolt could extend. Notably, these embodiments all employ the unique combination of a clamping action (to reduce vibration and provide maximum rigidity at the leading edge of the impact cutter blades), via a clamp point (or points), a pivot ridge, and an opposing leading edge contact line or ridge.

In some embodiments of an impact cutter blade and holder method, the clamping of the impact cutter blades150in the impact holders130achieves unique technological improvements. The combination of cooperating impact cutter blade details and impact holders details are used to achieve the proper clamping to reduce vibration and provide maximum rigidity at the leading edge of the impact cutter blades.

In some embodiments of the impact cutter blade and holder system100, the impact cutter blade and holder system100includes a cutter disk110; a plurality of impact holders130; a plurality of impact cutter blades150, wherein an impact cutter blade150is attached to each impact holder130; and a plurality of wear slugs180, wherein a wear slug180is attached to each impact holder130.

In other embodiments of the impact cutter blade and holder system100, the impact cutter blade and holder system100includes a cutter disk110; a plurality of impact holders130; a plurality of impact cutter blades150, wherein an impact cutter blade150is attached to each impact holder130; and a plurality of impact tabs190, wherein an impact tab190is secured between each impact holder130and associated impact cutter blade150.

In still other embodiments of the impact cutter blade and holder system100, the impact cutter blade and holder system100includes a cutter disk110; a plurality of impact holders130; a plurality of impact cutter blades150, wherein an impact cutter blade150is attached to each impact holder130; and a disk wear cover plate200.

Yet other embodiments are directed towards the impact holder130itself. In such an embodiment, the impact holder130secures to a cutter disk110; an impact cutter blade150, and an impact tab190. The impact cutter blade150is attached to the impact holder130, while the impact tab190is secured between the impact holder130and the impact cutter blade150.

Certain words and phrases used in the specification are set forth as follows. As used throughout this document, including the claims, the singular form “a”, “an”, and “the” include plural references unless indicated otherwise. Any of the features and elements described herein may be singular, e.g., a sensor may refer to one sensor and a memory may refer to one memory. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or,” is inclusive, meaning and/or. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. Other definitions of certain words and phrases are provided throughout this patent document.

Generally, unless otherwise indicated, the materials for making the invention and/or its components may be selected from appropriate materials such as metal, metallic alloys (high strength alloys, high hardness alloys), composite materials, ceramics, intermetallic compounds, and the like.

The foregoing description, for purposes of explanation, uses specific nomenclature and formula to provide a thorough understanding of the disclosed embodiments. It should be apparent to those of skill in the art that the specific details are not required in order to practice the invention. The embodiments have been chosen and described to best explain the principles of the disclosed embodiments and its practical application, thereby enabling others of skill in the art to utilize the disclosed embodiments, and various embodiments with various modifications as are suited to the particular use contemplated. Thus, the foregoing disclosure is not intended to be exhaustive or to limit the invention to the precise forms disclosed, and those of skill in the art recognize that many modifications and variations are possible in view of the above teachings.

These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the breadth and scope of a disclosed embodiment should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.