Patent Publication Number: US-10323364-B2

Title: Asphalt milling cutter arrangements

Description:
FIELD OF THE DISCLOSURE 
     The present disclosure relates to grinders in the form of a planer or drum grinder for milling surfaces such as asphalt or concrete. The planer has a multiplicity of cutters or grinding teeth oriented in selected arrangements. It is described in the context of a representative system that is added to prime movers, such as skid-steer loaders. 
     BACKGROUND 
     In normal use, a skid-steer loader has a loader bucket pivotally attached to two front lift arms. Optionally, the loader bucket of a skid-steer loader may be removed and alternate or auxiliary implements such as a planer may be attached to grind and remove hard surfaces such as pavement surfaces of concrete or asphalt such as in roads, bridges or parking lots. Such planers are sometimes called cold planers. 
     Common apparatus for grinding or planing away hard level surfaces such as asphalt roads or concrete roads commonly drive a rotating grinding cylinder or drum, the exterior surface of the drum has a multiplicity of cutters for grinding and cutting, typically teeth or carbide or diamond tipped cutters. The cutters can be replaced as they wear out. Such a grinding drum is commonly driven and controlled by a hydraulic machine which provides supporting and driving mechanisms for pressing the grinding drum against a flat surface to be ground or planed away, for rotatably driving the grinding drum causing its cutters to impinge upon the surface to be ground away, and for moving the grinding drum in a forward motion along the surface being ground. Typically, a cold planing apparatus incorporates a protective shroud to shield against flying debris. 
     In many cases, a surface planer is used to remove an area of material at a constant depth. In one version of the prior art, illustrated in  FIG. 2A , a grinder arrangement  50  is configured with a series of circular plates  52  vertically arranged and perpendicular relative to a shaft or axle. A series of cutters  54  such as grinding teeth are supported by and arranged around the perimeter of the plates. The plates  52  have a constant diameter. The cutting width of each plate is limited by the orientation of cutters  54 . For example, each plate may only be able to cut a width of 1½ to 2 inches. When used, as illustrated in  FIG. 2B , grinder arrangement  50  forms a cutting pattern formed as a single continuous slot  55  at an even depth. To form a continuous slot  55 , the paths of respective cutters  54  of adjacent plates  52  must be closely spaced and/or overlap to avoid leaving a grooved surface. However, the plate spacing is limited due to the physical mounting arrangement. The maximum width is also limited because power and mounting requirements limit the number of plates  52  which can be used. Further, a drawback or disadvantage of such grinding drums is that pulverized asphalt or concrete debris tends to pile up in front of and behind the grinding drum as it moves forward, creating unwanted resistance to forward motion and drum rotation, wasting energy and causing excess wear by re-grinding of the debris. 
     An improvement on grinder  50  with vertical plates is the elliptical disc arrangement disclosed in U.S. Pat. No. 5,791,737. An example is illustrated in  FIG. 3A . The elliptical disc grinder arrangement  60  includes an axle having four elliptical grinding discs  62  mounted thereon. A multiplicity of hardened grinding teeth or cutters  64  are spaced at intervals along the outer peripheral surfaces of the elliptical discs. 
     The elliptical plates  62  are tilted and fixed with respect to the axle. An elliptical plate  62  can be angled so that the path of its perimeter defines a cylindrical section relative to a shaft. When viewed along the axis of the shaft, the ellipse appears to be a circle. When such an elliptical plate is rotated about the shaft axis, all points on the ellipse edges orbit equidistant from the axis and the rotation defines a cylindrical section with a height and radius. The cutter paths all have the same radius around the axis of rotation, but may be offset laterally along the axis thus determining the cylindrical section height. The paths may be closely spaced or may overlap while the cutters are spaced in different spots along a shared orbit. This creates a continuous slot  65  of even depth ( FIG. 3B ). The tilted elliptical plates  62  allow a wider path to cut by each plate and its associated cutters. For example, each plate may cut a pattern in a width of 4 to 6 inches. The plate and cutter spacing also allows pulverized debris to pass between the plates to exit the grinder. 
     SUMMARY 
     Example embodiments include planers which may include shafts, plates and cutter arranged in specific orientations to obtain specialty cutting patterns. The arrangements may include angled elliptical plates defining cylindrical radii of different sizes. In some arrangements, the elliptical plates are arranged in combination with circular vertical plates. The planer can be mounted on a skid steer loader or similar support vehicle. The arrangements can be selected to form specific cutting patterns in a surface being ground, for example by an operator for the support vehicle. 
     In one embodiment, a planer for milling a surface includes a shaft to be moved over a surface to be ground in a direction of travel. At least one first elliptical plate is fixedly arranged in a non-perpendicular angle relative to the axis of rotation and carrying a set of cutters arranged so that as the shaft rotates, the cutters each orbit in a circle of constant radius around the axis of rotation defining a first circular cylindrical section with a first cylindrical radius. At least one second plate is also fixedly arranged on the shaft and carries a second set of cutters arranged so that as the shaft rotates about its axis of rotation the grinding teeth orbit circularly around the axis of rotation defining a second radius. The second radius differs from the first radius. 
     In some embodiments, the second plate is an elliptical plate. In alternate embodiments, the second plate may be a vertical circular plate. In one arrangement, a plurality of first elliptical plates and a plurality of second plates are arranged in an alternating pattern. In an alternate, arrangement, a plurality of first elliptical plates is arranged on opposing sides of a single second plate. 
     Some embodiments incorporate at least a third plate fixedly arranged on the shaft carrying a third set of cutters defining a third radius. The third radius is different from the first radius and the second radius. 
     Certain embodiments provide a planer for milling a surface including a shaft rotatably mounted along an axis of rotation. A first set of cutters is supported on the shaft and arranged in an angled elliptical pattern so that as the shaft rotates, the cutters each orbit in a circle at a first cylindrical radius around the axis of rotation. A second set of cutters is also supported on the shaft and arranged so that as the shaft rotates about its axis of rotation the cutters orbit circularly at a second radius around the axis of rotation. The second radius differs from the first radius. In some embodiments, the second set of cutters is arranged in an angled elliptical pattern relative to the axis of rotation. Alternately, the second set of cutters is arranged in a circular pattern perpendicular to the axis of rotation. 
     In further embodiments, a planer for milling a surface includes a shaft rotatably mounted along an axis of rotation. At least one angled plate is mounted with an apex portion coaxially aligned with the shaft. The plate includes a pair of portions angled in a concave arrangement diverging from the apex on opposing sides of the shaft. A set of cutters is arranged on the plate so that as the shaft rotates, each cutter orbits in a circle of constant radius around the axis of rotation and within a plane perpendicular to the axis of rotation. At least a first cutter on the plate is in a first vertical plane and defines a first radius, and at least a second cutter on the plate is in a second vertical plane and defines a second radius. The second radius is different from the first radius. In some embodiments, the cutters are arranged in a pattern extending from said apex along said angled portions, wherein the cutters are progressively spaced to define paths of increasing radii to make a substantially continuous angled cut. 
     Further forms, objects, features, aspects, benefits, advantages, and examples of the present disclosure will become apparent from a detailed description and drawings provided herewith. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of a representative arrangement with a grinder unit attached to a skid-steer loader. 
         FIG. 2A  is a front view of a prior art cutter arrangement. 
         FIG. 2B  illustrates the cutting pattern formed by the cutter arrangement in  FIG. 2A . 
         FIG. 3A  is a front view of a prior art cutter arrangement. 
         FIG. 3B  illustrates the cutting pattern formed by the cutter arrangement in  FIG. 3A . 
         FIG. 4A  is a front view of an embodiment of a cutter arrangement. 
         FIG. 4B  illustrates the cutting pattern formed by the cutter arrangement in  FIG. 4A . 
         FIG. 5A  is a front view of an embodiment of a cutter arrangement. 
         FIG. 5B  illustrates the cutting pattern formed by the cutter arrangement in  FIG. 5A . 
         FIG. 6A  is a front view of an embodiment of a cutter arrangement. 
         FIG. 6B  illustrates the cutting pattern formed by the cutter arrangement in  FIG. 6A . 
         FIG. 7A  is a front view of an embodiment of a cutter arrangement. 
         FIG. 7B  illustrates the cutting pattern formed by the cutter arrangement in  FIG. 7A . 
         FIG. 8A  is a front view of an embodiment of a cutter arrangement. 
         FIG. 8B  illustrates the cutting pattern formed by the cutter arrangement in  FIG. 8A . 
         FIG. 9  is a side view of the cutter arrangement of  FIG. 8A . 
     
    
    
     DESCRIPTION OF SELECTED EXAMPLES 
     For the purpose of promoting an understanding of the principles of the disclosure, reference will now be made to the examples illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications in the described examples, and any further applications of the principles of the disclosure as described herein are contemplated as would normally occur to one skilled in the art to which the disclosure relates. Certain examples of the disclosure are shown in detail; although it will be apparent to those skilled in the relevant art that some features which are not relevant to the present disclosure may not be shown for the sake of clarity. 
     Example embodiments include planers which may include shafts, plates and cutter arranged in specific orientations to obtain specialty cutting patterns. The arrangements may include angled elliptical plates defining cylindrical radii of different sizes. In some arrangements, the elliptical plates are arranged in combination with circular vertical plates. The planer can be mounted on a skid steer loader or similar support vehicle. The arrangements can be selected to form specific cutting patterns in a surface being ground, for example by an operator for the support vehicle. 
     Referring generally to  FIG. 1  there is shown a skid steer loader as an example support vehicle with a representative planer  28 . A typical skid steer loader  10  is a type of support vehicle having a frame  12 , four wheels  14  or tracks, an operator position, such as a cage or cab  16  with a seat  18 , and a pair of left and right front lift arms  20 . Left and right hydraulic cylinders  22  may be paired with lift arms  20 . Various work tool implements may be interchangeably mounted to the skid steer loader, for example by being coupled and uncoupled from the lift arms  20 . 
     As illustrated, an implement frame  30  is generally configured to be mounted to the left and right arms  20  of the skid steer loader and optionally the left and right hydraulic cylinders  22 . In a preferred embodiment, brackets are provided at the rear of the frame allowing the frame and planer apparatus  28  to be attached to the lift arms  20  and/or cylinders  22 . Left and right arms  20  and the left and right hydraulic cylinders  22  may function in concert to pivot the orientation of frame  30  and the planer. In a preferred embodiment, frame  30  is configured as a lateral piece, which may function as a debris shield and which may allow the planer to be mounted or moved to the left or right of the centerline of the skid-steer loader in the direction of travel D if desired. Optionally ground engaging elements such as rollers  32  are mounted adjacent the foot of the frame  30  to allow the frame to rest upon and roll over a support surface. 
     The skid-steer loader  10  may have a hydraulic power system, which may be selectively coupled directly or through an interface to certain work implements to provide hydraulic power to the implements. Example supply and return lines  24 ,  26  are shown. Generally the skid steer loader and any work implements are controlled by an operator through a control  19  located adjacent the operator position. In some skid steer loaders, the operator enters the operator position from the front of the vehicle. 
     In certain embodiments, a planer  28  is based on a grinder with grinding teeth known as cutters. The cutters are arranged around a rotatable shaft, for example on plates and located within a housing or shield which is level or angled and configured to move at a uniform height along or above a surface in a direction of travel. As the planer is moved, the cutters mill or grind the surface. The arrangement of plates and cutters along the axis within the grinder is sometimes called the grinding drum. Preferably, hydraulic power is supplied to rotate the shaft so that the cutters or teeth cut into the surface at a desired depth. The grinding drum shaft may be supported parallel to the surface for even cutting, or it may be angled if an angled cut profile is desired. The grinding drum is hydraulically driven by separate or shared hydraulic lines (not shown). 
     The planer may be mounted on a host machine, such as via a frame to a skid-steer loader, or it may operate independently, for example when mounted to an independent frame or trolley. The support vehicle, frame and/or the side plates are used independently or in cooperation to control the grinding depth of the planer. In certain embodiments, the planer housing is mounted to a support frame which supports the housing at a desired height to control the grinding depth of the grinding drum and which is movable to move the housing and grinding drum along the surface to be ground in the direction of travel D. 
     Selected disclosed cutter arrangements are improvements on a circular vertical cutter arrangement as illustrated in  FIG. 2A  or an elliptical cutter arrangement as illustrated in  FIG. 3A  and discussed in U.S. Pat. No. 5,791,737. In summary,  FIG. 3A  illustrates a cutter arrangement  60  with an axial shaft and a series of tilted elliptical plates  62  mounted to the shaft. Each elliptical plate has a pair of long radii. A series of cutters  64  are mounted around the perimeter of each plate. When appropriately angled, the perimeters of the elliptical plates form sections of a cylinder of constant radius R. When viewed along the rotational axis of the shaft, the elliptical plates are perceived as circular. The cutters are supported at the same radius and orbit around the axis of rotation but are offset laterally along the axis. The plates  62  are angled along the major axis of the ellipse. The plates can be angled in either direction relative to the shaft. When rotated, the cutter arrangement of each plate  62  cuts a cylindrical section with a constant radius R and with a respective cylindrical section height H 1 , H z , H 3 , H 4  defined by the axial offset of the plate ends along the shaft. The cylindrical total height H T  of arrangement  62  correspondingly defines a cut width measured along the length of the shaft. Consequently a wider cutting pattern  65  ( FIG. 3B ) can be achieved with an elliptical plate cutter arrangement  60  than the relatively narrow cutting pattern  55  that can be obtained by a vertical plate cutter arrangement  50  ( FIG. 2B ). 
     Planer  28  in  FIG. 1  is representative. The present disclosure teaches cutter arrangements, such as arrangements  110 ,  210 ,  310 ,  410 , and  510 , any one of which can be arranged on the shaft within the housing of planer  28 . In alternate embodiments, portions or variations of the cutter arrangements can be arranged in various permutations. 
       FIG. 4A  illustrates a cutter arrangement  110  with at least one and in this case five elliptical angled plates mounted on shaft  120 . Each plate includes a series of cutters  154  mounted around the perimeter of the plate. Arrangement  110  includes alternating angled elliptical plates  130 ,  140 . The cylindrical radius of plates  130  differs from the cylindrical radius of plates  140 . Correspondingly, plates  130  and  140  form cylindrical sections of greater and lesser radius. Arrangement  110  creates a cut pattern  115  ( FIG. 4B ) with a series of alternating upward and downward stepped portions forming a crenelated or notched pattern. 
     In certain uses, the crenelated cut pattern  115  provides advantages. For example a crenelated pattern may be advantageous when milling a portion of a surface to repair an area containing cracks. A repair process can be performed by first using a planer with plate arrangement  110  to grind cut pattern  115  into the surface, thereby removing a volume of material as debris. The volume of the removed area is then filled with a replacement material such as concrete or asphalt, which may be pressed into place, for example by rolling or stamping, and allowed to cure. Ideally, the new material bonds with the old material at the material interfaces to form a seal. As one advantage, the crenelated cut pattern  115  increases the contact surface area between the old milled surface and the replacement material. The increased contact area allows increased adhesion between the two materials. The alternating up and down stepped profile also creates a mechanical barrier or lock so that the replacement material is less likely to creep relative to the old material due to pressure or due to expansion or contraction based on ambient temperature variations. Another advantage is that the path for water infiltration is greatly increased over a straight narrow cut, reducing the risk of degradation due to freezing and thawing. 
     In an alternate embodiment,  FIG. 5A  illustrates a cutter arrangement  210  along shaft  220  with several angled elliptical plates  240  and cutters  254  defining smaller cylindrical radius arrangements on opposing sides of an angled central elliptical plate  230  defining a larger cylindrical radius. The arrangement creates a T cut pattern  215  ( FIG. 5B ). The T cut pattern includes a pair of parallel sections  216  at a relatively shallow depth with a width defined by the axial displacement of cutters  254  along plates  240 . The central plate  230  creates a central deeper section  218  with a width defined by the axial displacement of the cutters  254  along the axis of plate  230 . Arrangement  210  can also be used during a process of repairing cracks in the pavement. The T cut pattern increases the surface area of adhesion between the original material and replacement material, and may allow greater mass of material to be used with a deeper portion to help anchor the replacement material in place. The stepped pattern also distributes the traffic load over the repaired portion over a wider area. Another advantage of a T cut pattern is that the path for water infiltration is greatly increased over a straight narrow cut, reducing future degradation due to freezing and thawing. 
     As a variation of a T cut profile,  FIG. 6A  shows a cutter arrangement  310  with cutters  354  supported on a series of angled elliptical plates and a circular vertical plate along shaft  320 . The plates include a series of elliptical plates  340  defining smaller cylindrical radius arrangements on opposing sides of a central vertical plate  330  with a circular radius larger than the cylindrical radius of plates  340 . 
     Arrangement  310  creates a cut pattern  315  ( FIG. 6B ) with a slot cut profile. The pattern  315  includes a pair of parallel sections  316  at a relatively shallow depth with a width defined by the axial displacement of the cutters  354  along plates  340 . The central plate  330  creates a central slot cut  318  with a relatively thin width yet significantly greater depth corresponding to the cutters on plate  330 . 
     In an exemplary use, arrangement  310  can be used as trenching tool during fiber optic cable installation. Currently a microtrencher is often used when installing fiber optic cables in streets and other areas of asphalt. A microtrencher typically makes a narrow ½ inch to 2½ inch straight sided cut. The cut is filled after a cable is placed in the cut. Currently there is no standard width or depth of this cut with each community making its own specification. When arrangement  310  is used, the illustrated slot cut  318  creates a narrow slot or trench with straight sides. A cable can be placed in a protected position within slot  318  and then covered by replacement material to fill pattern  315 . Cut pattern  315  can be used to assist in cable installation and also has the advantages discussed with respect to cut pattern  215  discussed above. In alternate embodiments, a vertical circular plate  330  can be used with other arrangements, such as those illustrated in arrangements  110 .  210 ,  410  or  510 , to add a slot cut feature to the respective cut pattern. One or more vertical plates to make slot cuts can be used to place slots at either end or desired mid points in the cut pattern. 
     In an alternate embodiment,  FIG. 7A  illustrates cutter arrangement  410  with a series of angled elliptical plates with different cylindrical radii in stepped diameters along shaft  420 . In the example illustrated, arrangement  410  includes a plates  440  defining smaller cylindrical radii adjacent opposing ends of shaft  420 . A series of plates  434 ,  432  of increasing cylindrical radii converge towards a central plate  430 . Central plate  430  defines the largest cylindrical radius. Correspondingly, the cut pattern  415  of cutters  454  forms a stepped series of cuts with the depths increasing from the opposing ends toward the center. Outer steps  416  are the shallowest, with steps  417 ,  418  increasing in depth to the deepest step  419 . This creates a stepped V-cut pattern. The V-cut pattern can be useful in various contexts and also has advantages of greater surface area, lower water infiltration, greater mass and resistant to creep as discussed above. In alternate embodiments, the series of plates can have larger radius cut patterns at the ends converging to a smaller central radius, or the plates can be arranged in an increasing or decreasing series across the shaft to form a series of increasing or decreasing depth steps. In still further embodiments, a series of plates in multiple diameters can be arranged in various permutations to arrange desired asymmetric and/or customized patterns of shallower, deeper and interim depth steps. 
       FIGS. 8A and 9A  show cutter arrangement  510  with a central plate and a pair of angled plates along shaft  520 . Central plate  530  is vertical and creates the deepest or apex portion of cut pattern  515  ( FIG. 8B ). Alternately, central plate  530  could be an elliptical plate angled to define a cut pattern of a desired width. Angled plates  540  are bent or curved and arranged on opposing sides of central plate  530  with concave portions facing plate  530 . Each plate  540  includes a central vertex  542  mounted to and aligned with shaft  520 . A pair of angled portions  544  diverge horizontally and upward/downward from vertex  542 . The angled portions may be linear or curved. From the perspective of  FIG. 8A , angled portions  544  have surfaces or faces which diverge upward and downward and also extend laterally inward to tip portions  546  with a maximum radius approximately matching the radius of central plate  530 . As illustrated from an end view in  FIG. 9 , bent plates  540  are also vertically tapered to tip portions  546 ; forming somewhat triangular shaped upper and lower portions with two curved edges. 
     The cutters  554  on each V-plate are arranged in a pattern extending inward from each vertex  542  along a corresponding angled portion  544  toward the middle with increasing cylindrical radii around the axle. The upper and lower angled portions  544  are continuous as they extend inward. Accordingly, for example, cutters  554  each orbit in a circle of constant radius yet a first cutter in vertical plane V 1 , has a first radius which is different from a second radius defined by a second cutter in vertical plane V 2 . Angled portions  544  provide four edges in each vertical or perpendicular plane. Cutters  554  can be placed on different plate edges within the same vertical plane with closely adjacent and/or overlapping paths. 
     A progressive arrangement of cutters  554  with increasing and decreasing orbits in arrangement  510  creates a substantially continuous and relatively smooth and sloped pattern cut, for example creating V-cut pattern  515 . V-cut pattern  515  includes a pair of angled sides  516  extending to a deepest portion  518 . In one arrangement the cutters  554  in each geometric perpendicular plane are of the same radius. Alternately, a pattern of cutters within a shared perpendicular plane, for example along four edges in plane V 2 , may be angled inward and outward in an alternating pattern, with the outward angled cutters having a slightly smaller orbit radius. 
     While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred example has been shown and described and that all changes, equivalents, and modifications that come within the spirit of the disclosures defined by following claims are desired to be protected.