DOUBLE-SIDED WEAR INSERT FOR A CHIPPER

Field of the Invention

The present invention relates to a wear insert for a disc, drum or conical head style chipper.

Background

Disc, drum, and conical head chippers are basic equipment in sawmills, used for processing logs into useable lumber. They employ revolving chipper heads in either disc, drum, or conical configurations to which, typically, a number of knives are attached. In a disc chipper (or chipper disc) the knives may be attached to the periphery of the disc or the sides of the disc. In drum and conical head chippers, the knives are attached to the periphery of the drum. Any of these chippers will be referred to hereinafter simply as a "chipper," and either a disc, drum, or conical head will be referred to simply as a "cutting head" or "head."

The knives are typically clamped to the head between a pair of clamping members, an "outer" or "upper" clamping member, and an "inner" or "lower" clamping member that is attached to the base of the chipper. The knife has front and back sides, the former facing the direction of rotation of the head. The upper clamping member contacts the back side and the lower clamping member contacts the front side, clamping the knife therebetween.

The wood article to be chipped by the chipper is fed into the chipper at a given feed speed, the cutting head revolves at a given rotational speed, and the knives have a given knife density, i.e., they are angularly spaced apart from one another on the head a given amount. These three parameters determine the size, particularly the

length, of the chips. While the wood article is chipped fundamentally to shape it into useable lumber, the chips themselves have economic value as components of engineered or manufactured wood products, such as pulp and paper, fiberboard, and oriented strand board. The knife is typically removed from the chipper head by removing the upper clamping member. In some more advanced prior art systems, the knife can be removed by a threaded adjustment that pivots the lower clamping member, such as described in Swartwood et al., U.S. Patent No. 5,979,522.

Figure 1 shows, in cross-section, a generic knife assembly 2 for clamping a chipper knife. The knife assembly 2 is mounted to a chipper head 4. The assembly has four main components, a knife 5, an upper clamping member (or "clamp") 6, a lower clamping member (or "holder") 7, and a replaceable wear insert 8. The clamp 6 and holder 7 clamp the knife, and a bolt 11 passes through the clamp and into, or through, the holder. The assembly rotates in the direction "R." The knife has a front side 3 and a back side 4, the front side facing the direction of rotation R. Chips cut by the knife follow the path "P" and contact a wear surface 9 of the wear insert 8. The wear surface becomes worn as a result of this contact. The wear surface, since it is closest to the knife, experiences more wear than the holder 7. The wear insert 8 is substantially smaller (less massive) than the holder 7. For this reason, and because the greatest amount of wear occurs in the localized area of the wear insert, it is economically advantageous to provide, in addition to the holder 7, the wear insert as a disposable part. The wear insert is also, typically, substantially

smaller than the clamp. The wear insert may or not be bolted to the holder; however, it is not bolted to the clamp.

The wear insert is typically provided with a "wear coating," that is applied to and hardens the wear surface 9. One example is referred to more particularly as a "hardsurface," which results from hardsurfacing, i.e., the application to the wear surface 9 of a diamond carbide powder coating. With a wear coating, the wear surface is harder or more wear resistant than the tool steel of which it, and particularly the holder, is formed. Alternatively, the entire wear insert may be formed of a harder or more wear resistant material. The term "counterknife" is sometimes used to refer to a wear insert. However, a counterknife is defined more generally as a part used for breaking and deflecting chips cut by the knife, and the term has consequently been applied to holders in assemblies that do not contain a separate wear insert. Herein, the term wear insert is used to refer to a specific, relatively small component of an assembly like the assembly 2.

Figure 2 shows two important parameters relating the knife 5 and wear insert 8. The impact angle θ determines the "impact" of the cutting head on the chips. In a "high impact" configuration, θ = 90 degrees and the wear surface 9 is a blunt obstacle to chip flow. To provide lower impact configurations, θ is increased resulting in a more gentle path for chip flow. It is desired to break the chips with only as much force as is necessary, to minimize wear and damage to the chips, so the impact angle is adjusted for various factors, including the strength of the wood being chipped.

The other important parameter shown in Figure 2 is the depth "D" of the wear insert relative to the cutting edge CE of the knife. This parameter is adjusted to be appropriate for the chip length mentioned above.

Referring back to Figure 1, the wear insert 8 is indexed to the holder 7 by a side of the wear insert 10a abutting the holder at a seat 10b of the holder. As the insert wears and the wear surface 9 erodes, the surface retreats in the direction of the seat 10b and the depth D is undesirably increased. When the wear has become unacceptable, the wear insert is removed and either the wear surface renewed or the part replaced. It may be noted that the above discussion is based on a simplifying assumption that the knife does not wear appreciably relative to the wear insert. This is generally not true, so the actual relationship between wear of the wear insert and the depth parameter "D" is of course more complex than indicated.

Providing the wear insert, especially as a disposable part in a knife assembly like the assembly 2, is economical, however, it remains that the part must be replaced or reworked at intervals, and it would be desirable to increase the service life of the wear insert.

Summary A double-sided wear insert. The wear insert is for use in a knife assembly that includes a knife, a clamp, and a holder. Wear inserts according to the invention can either be turned end-for-end, of flipped up-side down, to double the service life of the part. Four more particular embodiments are summarized as follows.

In first, second and third embodiments, the wear insert includes two planar wear surfaces at opposite sides thereof. Li the first and second embodiments, the wear insert defines at least one of (a) a plane about which the wear surfaces have reflective symmetry or (b) an elongate axis of the wear insert about which the wear surfaces have 180 degree rotational symmetry. More particularly, in the first embodiment, the wear surfaces define equal impact angles that differ substantially from 90 degrees, and in the second embodiment, the wear surfaces are harder or more wear resistant than at least some portions of the holder.

In the third and fourth embodiments, the wear insert has an upper side for contacting the knife and an opposite, lower side that is received by the holder. More particularly, in the third embodiment, the lower side includes a holder-indexing feature that includes at least one of (a) a projection and (b) a recess for indexing the wear insert to the holder, and in the fourth embodiment, the upper side includes at least one knife- indexing feature that defines in cross-section a contour that is a smoothly varying arc, for indexing the knife. Consistent with either turning the wear insert, or flipping the wear insert, either the upper surface has two of the knife- indexing features, in which case the knife-indexing features have reflective symmetry, or both the upper and lower surfaces have one of the knife-indexing features, in which case the knife-indexing features have 180 degree rotational symmetry.

It is to be understood that this summary is provided as a means of generally determining what follows in the drawings and detailed description and is not intended to limit the scope of the invention. Objects, features and advantages of the invention

will be readily understood, upon consideration of the following detailed description taken in conjunction with the accompanying drawings.

Brief Description of the Drawings Figure 1 is a cross-sectional view of a generic, prior art knife assembly.

Figure 2 is a cross-sectional view of knife and wear insert components of the assembly of Figure 1.

Figure 3 is a cross-sectional view of a first knife assembly including a preferred double-sided wear insert according to the present invention.

Figure 4 is a cross-sectional view of the preferred double-sided wear insert component shown in Figure 3. Figure 5 is a cross-sectional view of a second knife assembly including the double-sided wear insert of Figure 3.

Figure 6 is a back-side isometric view of the preferred knife component shown in Figure 3.

Figure 7 is a front-side isometric view of the knife of Figure 6. Figure 8 is a cross-sectional view of the knife of Figure 6, taken along a line

8-8 thereof.

Figure 9 is an upper-side isometric view of the wear insert of Figures 3 and 4.

Figure 10 is a cross-sectional view of an alternative wear insert according to the invention that differs from the wear insert of Figure 5 in that it provides for flipping, rather than turning, of the wear insert to provide fresh wear surfaces.

Figure 11 is a cross-sectional view of the knife assembly of Figure 3 with the wear insert of Figure 10 substituted for the wear insert of Figure 3.

Figure 12 is a cross-sectional view of another alternative wear insert that illustrates a variation of the wear insert of Figure 10.

Figure 13 is a cross-sectional view of yet another alternative wear insert that illustrates another variation of the wear insert of Figure 10. Figure 14 is a cross-sectional view of a third knife assembly including another double-sided wear insert for use with an alternative knife.

Detailed Description of Preferred Embodiments Reference will now be made in detail to specific preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.

Referring to Figure 3, a knife assembly 20 for use with a chipper head is shown having a knife 25, a clamp 23, and a holder 24 and a double-sided wear insert 22 according to the present invention. The clamp and holder clamp the knife therebetween by the use of clamping bolts 21 passing through the clamp and into or through the holder.

The wear insert 22 is of the same general type of component as the wear insert 8 described above in connection with Figures 1 and 2. It is substantially less massive than the holder 24, typically about 1/6 of the mass of the holder, and in this example

is bolted to the holder by use of a mounting bolt 21a. The wear insert 22 is disposed between the knife 25 and the holder 24, and it is characteristic of a wear insert, because of its relatively small size, that it does not make contact with the clamp 23. Preferably, at least a wear surface 31 of the wear insert that is proximate the knife 25 is harder or more wear resistant than the holder. This is because the wear insert is exposed to the greatest chip quantity and impact velocity and is therefore subject to the most wear. It should be understood that, while having a higher hardness generally ensures a greater wear resistance, it is possible to provide a higher wear resistance without increasing the hardness, and a material may provide a greater wear resistance despite a decrease in hardness.

It is also generally, though not necessarily, the case that the wear insert 22 is substantially less massive, and that the wear surface 31 is harder or more wear resistant than the clamp 23.

In the preferred embodiment of the wear insert 22, the wear surface 31 is provided with a wear coating to produce a hardness or wear resistance that is greater than that of the material of which the holder is formed. Typically, the holder and clamp are formed of tool steel, and the wear coating provides a hardness of about 63 - 65 Rockwell C. A preferred alternative is to form the entire wear insert of a harder or more wear resistant material than that of which the holder is formed, such as a tool steel that has been heat treated to provide a hardness in the above-mentioned range.

However, though it is desirable, it is not essential that the wear insert be made any harder, or more wear resistant, than the holder or the clamp.

While one wear surface 31 is indicated in Figure 3, it is an outstanding advantage of the invention that a single wear insert provides at least two, selectable wear surfaces as described below.

Shown in the knife assembly ^" 20 is a preferred knife 25. The knife 25 will be described in greater detail below, however, it should be immediately understood that a double-sided wear insert according to the present invention may be used in conjunction with any prior art or future developed knife.

Figure 4 shows the preferred wear insert 22 apart from the assembly 20. The wear insert has an elongate cross-section (as shown), an upper side "TS" that faces the knife 25 and a lower side "LS" that is received by the holder 24.

The wear insert 22 is entirely symmetric about a plane of reflective symmetry "POS. " A line "E" perpendicular to POS and lying in the plane of the Figure defines an elongate (as shown in cross-section) direction or axis of the wear insert. The line E shown intersects two points "Pa" and "Pb" at opposite sides of the wear insert that have reflective symmetry about POS and, in this embodiment, define the maximum width "W" of the wear insert 22.

As mentioned, two wear surfaces 31, namely 31 a, 3 Ib, are provided, at the opposite sides of the wear insert. One of the wear surfaces (31a) is positioned below the knife 25 for active use, while the other wear surface (3 Ib) is stowed within the knife assembly 20. When the wear surface 31a becomes worn to an unacceptable degree, the wear insert 22 is removed, turned end-for-end (referred to herein as "turning"), and replaced to expose the previously stowed wear surface 31b. This provides the outstanding advantage of doubling the use that can be obtained from the wear insert 22 before it must be renewed, reworked, or disposed of.

The wear surfaces 31 are planar, but this is not essential. Preferably, the wear surfaces 31a, 31b are substantially or essentially identical. And typically, as is shown in Figure 4, both wear surfaces define the same impact angle θ described above in connection with Figure 2 relative to the axis E. The impact angles are considered equal on both sides of the wear insert for all purposes herein where the same angle is obtained from the wear insert when the wear insert is turned.

" Impact angles are provided as desired according to known criteria, and it is intended that a number of different wear inserts having different impact angles may be used in the same knife assembly. It is not essential that the wear surfaces 31 of the same wear insert define the same impact angle, and it may be advantageous to provide different impact angles to allow for a predetermined adjustment of impact angle.

Figure 5 shows a knife assembly 20' like the knife assembly 20 except that a variation of the holder 24, i.e., 24' is used. The holder 24' includes a land 19 that contacts the end of the wear insert that is stowed within the assembly, to further stabilize it. The knife 25, however, preferably does not actually contact the wear insert 22 along a planar knife-edge-joining portion 27a of the knife, in either the assembly 20 or the assembly 20' (this feature is shown more clearly in Figure 14).

Returning to Figure 4, the upper side TS of the wear insert 22 includes identical knife-indexing features 32, namely 32a and 32b, that conform to and are therefore defined by complementary shaped indexing features 30 (Figure 3) of the knife, described below. While a particular complementary pair of shapes is shown, any other complementary shapes could be used. While the wear insert 22 is entirely symmetric about the plane of symmetry POS, this is not essential. Regardless, it is

independently desirable that the knife-indexing features 32 be symmetric about POS, to retain the same location of the wear surface relative to the knife after turning the wear insert. This is because (a) the knife is preferably also double-sided with two cutting edges, and symmetric about its own plane of reflective symmetry, so that the knife installed with either cutting edge in an active position may be used with the wear insert installed with either wear surface in an active position, and (b) even if the knife is not symmetric, the wear insert can be turned without changing or turning the knife.

The lower side LS includes a holder-indexing feature 40 that conforms to and is therefore defined by a complementary shaped indexing feature 42 (Figure 3) of the holder. While a particular complementary pair of shapes is shown, any other complementary shapes could be used, and the indexing feature 40 may include a projection or recess, or both. The provision of the holder-surface indexing feature 40 is an outstanding advantage of the invention, facilitating practical use of the two wear surfaces 31. Particularly, it has been determined that an end of the wear insert, because it is defined by a wear surface, does not provide acceptable indexing when abutted against a corresponding seat in the holder as in the prior art. This is due partly to the fact that the wear surface 31 can be at any desired impact angle and therefore will not generally be at the same angle as the seat, and partly to the fact that, preferably, the wear surface has a wear coating, and is most preferably hard surfaced, which leaves the wear surface loosely toleranced. Accordingly, as shown in Figure 3, the side 22a of the wear insert that is stowed within the knife assembly 20 is spaced from the holder 24 to accommodate this tolerance.

The holder-indexing feature 40 is also symmetric with respect to the plane POS so that each wear surface will occupy the same active position when the wear insert is turned.

Details regarding the preferred knife 25 are provided next. It should be understood that while preferred, it is not essential to the invention to use a knife having the particular features disclosed herein. The knife 25 with the features described herein is preferable, however, for reasons that will be explained.

The knife 25 is shown in perspective in Figures 6 and 7, and in cross-section in Figure 8. The knife has a back side 12a and a front side 12b. As will be understood by persons of ordinary skill, the front side 12b faces the direction of rotation of the cutting head, and for purposes herein, a vector pointing from the back side toward the front side will be considered to point in a "positive" direction.

The knife is elongate along an axis "EA" and has the cross-section shown in Figure 8. By comparison, with reference to Figure 9, the wear insert 22 is similarly elongate along an axis "EB" and has the cross-section shown in Figure 5. The knife has a plane of reflective symmetry "POS _1n ,^" comparable to the plane of reflective symmetry POS of the wear insert. With this symmetry, the knife 25 can be removed from the assembly 20, turned end-for-end to provide a fresh cutting edge, and reinstalled. The line E described above lies in a reference plane "B" shown in Figure 9 which is analogous to the reference plane "A" shown in Figure 8. These reference planes are perpendicular to the respective planes of reflective symmetry.

As shown in Figure 8, the knife has two parallel cutting edges 26 lying in the reference plane A, the edges referenced as 26a and 26b. The front side 12b includes two substantially planar knife-edge-joining portions 27, namely 27a and 27b that may

also lie in the plane A, but which may be disposed at non-zero angles with respect to the plane A if desired. For example, even if the knife-edge-joining portions are originally provided to lie in the plane A, these surfaces may be ground as known in the art to alter the attack angle of the knife 25. Between the knife-edge-joining portions 27, and projecting from the front side

12b of the knife 12, is a single deflector ridge 28. The deflector ridge 28 reaches a linear edge or line of points "L" of greatest maximum projection of the knife in the direction "Dl" indicated by the arrow (Figures 7, 8), from the plane A ₅ the line lying in the plane of reflective symmetry "POS _knife " of the knife. With particular reference to Figure 8, the deflector ridge 28 has two canted outer surfaces 29, namely 29a and 29b, joining at an apex 29c that is preferably sharp, but which in typical practice is slightly rounded-off, and where the amount of such rounding is not particularly important. The outer surfaces 29 may be substantially planar as shown, or may be concave and, preferably, smoothly curving. The deflector ridge 28 provides, in the outer surfaces 29, a guiding surface for efficiently guiding cut chips away from the apparatus. This guiding action also reduces wear of the wear insert 22 as a result of preventing some contact with the chips that would otherwise occur. Further, a single deflector ridge may be made larger than the corresponding deflector ridges of a deflector ridge pair, as had been previously provided in the prior art, without any additional metal being required.

This provides for a stronger deflector ridge that is also more capable of providing the aforedescribed functions with no increase in the weight of the knife 25. It also provides for a stronger knife by distributing more metal farther from the neutral axis, as in an I-beam.

The front side 12b of the knife 25 includes a pair of indexing features 30, namely 30a and 30b, as mentioned above. The indexing features 30 help, along with the deflector ridge 28, to index the knife to the wear insert 22 also as discussed above.

Each indexing feature 30 is disposed between the corresponding knife-edge- joining portion 27a, 27b and the deflector ridge 28. That is, distal sides "DSl" of the indexing features 30 merge with proximal sides "PSl" of the knife-edge-joining portions 27 at points "Q," and proximal sides "PS2" of the indexing features 30 merge with distal sides "DS2" of the outer surfaces 29 of the deflector ridge 28 at points "R." Due to the symmetry of the knife, the points Q on both sides of the plane of symmetry POS define a plane "B," which in this example is coincident with the plane A but need not be as mentioned above. The orientation of the knife shown in Figure 8 is a drawing convention in which the front side of the knife is at the bottom of the Figure, so that the positive direction "Dl" is downward. The indexing features 30 describe re-entrant contours "C" that intersect the plane B at points Q, and points "S" on these contours are points of minimum projection of the front side 12b of the knife with respect to the positive direction Dl .

This re-entrant disposition of the indexing features 30 provides the advantage of tucking the indexing features up and out of the way of chip flow so that, as the knife-edge-joining portions wear, the indexing features remain in substantially unworn condition.

Further, each contour C is preferably shaped as a concave, smoothly varying arc that smoothly merges with the corresponding outer surface 29a, 29b of the deflector ridge 28. In correspondence, the complementary feature 32 of the wear

insert 22 is a convex, smoothly varying arc. More preferably, these arcs are circular, which is found to provide for maximally robust registration of the knife.

Thus far, a wear insert having wear surfaces that are symmetric about a plane of reflective symmetry has been shown and described as preferred. This allows for ^• turning the wear insert end-for-end to provide a change of wear surfaces. However, it essentially the same functionality may be provided in a wear insert having 180 degree rotational symmetry about the elongate axis EB. This allows for "flipping" the wear insert up-side down to provide the change of wear surfaces. Figure 10 shows such a wear insert 50 for comparison with the wear insert 22 of Figure 4. The wear insert 50 has wear surfaces 51 , namely 51a and 51 b that have 180 degree rotational symmetry instead of reflective symmetry, though they could also have reflective symmetry under certain circumstances.

The upper and lower sides TS and LS are identical and are also symmetric with respect to 180 degree rotations about the elongate axis EB. Knife-indexing features 52, namely 52a and 52b, are shaped to fit the knife as for the corresponding features 32 of the wear insert 22.

Identical holder-indexing features 60 are provided on both the upper and lower sides of the knife to accommodate flipping the wear insert and registering the wear surfaces 32a and 32b in the same position in the knife assembly. With additional reference to Figure 11, it will be appreciated that these features are recesses rather than projections to avoid interference with the knife 25. However, projections could be used where the knife has an accommodation for them.

While the holder-indexing features 60 are shown as being symmetric about a line perpendicular to the line E that intersects the axis EB, it will be readily

appreciated that reflective symmetry of the holder-indexing features is not important in this embodiment. For example, Figure 12 shows the wear insert 50 with the same basic configuration of the holder-indexing features without reflective symmetry but retaining the required 180 degree symmetry. The impact angles θ for the wear surfaces 51 are defined as indicated in Figure 12.

Figure 13 shows another variation of the wear insert 50 illustrating a circumstance in which points Pa and Pb defining the line E as defined above do not define the maximum width of the wear insert.

It follows from the above that, where the knife is suitably adapted, reflective symmetry like that of the wear insert 22 and 180 degree rotational symmetry like that of the wear insert 50 could be combined to produce a wear insert having four wear surfaces that can be selected by either or both turning or flipping the wear insert. Accordingly, it is not a requirement of the invention that a double-sided wear insert have only two wear surfaces. Figure 14 shows a double-sided wear insert 70 having reflective symmetry suitable for use with another preferred prior art knife described in Schmatjen, U.S. Patent No. 5,819,826, incorporated by reference herein. The wear insert 70 has a holder-indexing feature 74, two wear surfaces 75, namely 75a, 75b, and two knife- indexing features 76, namely 76a, 76b, functioning as described above for the equivalent features of the wear insert 22. The construction of a corresponding double-sided wear insert having rotational symmetry will be readily apparent in view of the discussion above concerning the wear insert 50.

It is to be understood that, while a specific double-sided wear insert has been shown and described as preferred, other configurations and methods could be utilized,

in addition to those already mentioned, without departing from the principles of the invention.

The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions to exclude equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.