Cross-Reference to Related Applications

[0001] This application claims the benefit of priority under 35 U.S.C. §119 of U.S.

Provisional Application Serial No. 63/392319 filed on July 26, 2022, the content of which is relied upon and incorporated herein by reference in its entirety.

Field of the Disclosure

[0002] The present disclosure is directed generally to sanding assemblies and machines used to sand parts, and more specifically to low-friction sanding assemblies and machines used in the edge beveling of parts.

Background

[0003] Grinding and/or sanding are useful steps in the manufacturing of numerous components and parts. In some cases, grinding and/or sanding are necessary steps to produce high-quality products. For example, when manufacturing parts such as ceramic honeycomb bodies to be used as filters and/or substrates within exhaust and/or filtration systems, sharp edges can result in excessive chipping of the part when the part undergoes downstream processing. Edge grinding (i.e., beveling) technology can be used to remove sharp edges of such parts. However, variations in the part shape can lead to uneven or inconsistent removal.

Summary of the Disclosure

[0004] According to an embodiment of the present disclosure, a low-friction sanding assembly is provided. The low friction sanding assembly comprises: a sanding pad configured to receive an abrasive device at a first surface of the sanding pad; and a constant-force assembly contacting a second surface of the sanding pad, wherein the constant-force assembly comprises one or more guiding elements and an actuator, the constant-force assembly being configured to maintain a target force between the abrasive device and an edge of a part to be sanded. [0005] In an aspect, the low-friction sanding assembly comprises an abrasive device contacting the first surface of the sanding pad, the abrasive device having at least one abrasive surface that faces away from the sanding pad.

[0006] In an aspect, the sanding pad is operatively connected to a feeding assembly comprising a feed motor, a gearbox, and a feed roller, the feed roller being configured to be in operational contact with the abrasive device, and the feed motor and the feed roller are configured to feed at least a second abrasive device to the first surface of the sanding pad.

[0007] In an aspect, the abrasive device is an abrasive belt.

[0008] In an aspect, the second surface of the sanding pad opposes the first surface of the sanding pad.

[0009] In an aspect, the actuator of the constant-force assembly is a pneumatic cylinder comprising a glass cylinder, a graphite piston disposed within the glass cylinder, and a cylinder rod extending from the graphite piston to the second surface of the sanding pad.

[0010] In an aspect, the cylinder rod of the actuator is operatively connected to the second surface of the sanding pad via a universal joint.

[0011] In an aspect, operation of the actuator creates less than 0.6 lbs. of friction.

[0012] In an aspect, each of the one or more guiding elements comprises a porous graphite air bushing that houses a guiding shaft, the guiding shaft being configured to contact the second surface of the sanding pad.

[0013] In an aspect, the constant-force assembly comprises an electromagnetic actuator.

[0014] In an aspect, the actuator of the constant-force assembly generates a preload force acting on the sanding pad opposite to a working direction such that the preload force compensates for the weight of the sanding pad.

[0015] In an aspect, the constant-force assembly comprises at least two guiding elements.

[0016] In an aspect, the at least two guiding elements are parallel with one another.

[0017] According to another embodiment of the present disclosure, a low-friction beveling machine is provided. The low-friction beveling machine comprises: at least a first low-friction sanding assembly secured to a first mounting plate, wherein the first low-friction sanding assembly is configured to present the sanding pad of the first low-friction sanding assembly to an associated part to be sanded at a first target beveling angle. In an aspect, the first low-friction sanding assembly comprises: a sanding pad configured to receive an abrasive device at a first surface of the sanding pad; and a constant-force assembly contacting a second surface of the sanding pad, wherein the constant-force assembly comprises one or more guiding elements and an actuator, the constant-force assembly being configured to maintain a target force between the abrasive device and an edge of a part to be sanded.

[0018] In an aspect, the first low-friction sanding assembly is secured to the first mounting plate via the constant-force assembly of the first low-friction sanding assembly.

[0019] In an aspect, the first target beveling angle is between about 5° and about 85° relative to a face of the associated part to be sanded.

[0020] In an aspect, the first low-friction sanding assembly further comprises an abrasive device contacting the first surface of the sanding pad, the abrasive device having at least one abrasive surface that faces away from the sanding pad;

[0021] In an aspect, the low-friction beveling machine comprises at least a second low- friction sanding assembly secured to a second mounting plate, wherein the second low-friction sanding assembly is configured to present the sanding pad of the second low-friction sanding assembly to an associated part to be sanded at a second target beveling angle. The second low- friction sanding assembly comprises: a sanding pad configured to receive an abrasive device at a first surface of the sanding pad; and a constant-force assembly contacting a second surface of the sanding pad, wherein the constant-force assembly comprises one or more guiding elements and an actuator, the constant-force assembly being configured to maintain a target force between the abrasive device and an edge of a part to be sanded.

[0022] In an aspect, operation of the constant-force assembly of the first low-friction sanding assembly and/or operation of the constant-force assembly of the second low-friction sanding assembly creates less than 0.6 lbs. of friction.

[0023] In an aspect, each actuator of the first and second low-friction sanding assemblies are one of a pneumatic cylinder actuator and an electromagnetic actuator, and each of the constant-force assemblies comprise at least two guiding elements, the at least two guiding elements of the first low-friction sanding assembly being parallel with one another, and the at least two guiding elements of the second low-friction sanding assembly being parallel with one another.

[0024] These and other aspects of the various embodiments will be apparent from and elucidated with reference to the embodiment(s) described hereinafter. Brief Description of the Drawings

[0025] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the various embodiments.

[0026] FIG. 1 is a perspective view of a low-friction sanding assembly illustrated according to aspects of the present disclosure.

[0027] FIG. 2 is a perspective view of a first cross-section of a low-friction sanding assembly illustrated according to aspects of the present disclosure.

[0028] FIG. 3 is a perspective view of a second cross-section of a low-friction sanding assembly illustrated according to aspects of the present disclosure.

[0029] FIG. 4 is a perspective view of a low-friction sanding machine illustrated according to aspects of the present disclosure.

[0030] FIG. 5 is a perspective view of a low-friction sanding assembly with a backing plate according to aspects of the present disclosure.

[0031] FIG. 6A is a photograph showing a portion of a part having a beveled edge according to aspects of the present disclosure.

[0032] FIG. 6B is a photograph showing the beveled edge of the part according to aspects of the present disclosure.

Detailed Description of Embodiments

[0033] The present disclosure is directed to low-friction sanding assemblies and machines used to grind and/or sand parts. More specifically, the sanding assemblies and machines of the present disclosure find particular application in the edge beveling of parts such as ceramic honeycomb bodies that can be used as filters and/or substrates within exhaust and/or filtration systems. The low-friction sanding assemblies and machines utilize the rotation of the part to guide the edge beveling process and enable the creation of consistent edge bevels of less than about 1 mm regardless of the variations in the shape of the part.

[0034] Turning to FIG. 1, a low- friction sanding assembly 100 is illustrated according to aspects of the present disclosure. In embodiments, the sanding assembly 100 comprises a sanding pad 102, an abrasive device 104, and a constant-force assembly 106. [0035] In an aspect, the sanding pad 102 is configured to receive the abrasive device 104 at a first surface 108 of the sanding pad 102. That is, in embodiments, the abrasive device 104 has a first surface 110 that contacts the first surface 108 of the sanding pad 102, and a second surface 112 that faces away from the first surface 108 of the sanding pad 102. In an aspect, the first surface 110 of the abrasive device 104 is a non-abrasive surface or layer that is not used for sanding and/or grinding, while the second surface 112 of the abrasive device 104 is an abrasive surface or layer that is adapted to sand and/or grind another object, such as a part.

[0036] In embodiments, the abrasive device 104 can be, for example and without limitation, a paper, sheet, block, or belt. In an aspect, the abrasive device 104 and/or the abrasive layer 112 of the abrasive device 104 comprises: aluminum oxide; a ceramic; garnet and flint sandpaper; silicon carbide; cubic boron-nitride; diamond; and/or combinations thereof. The abrasive layer 112 of the abrasive device 104 can have a coarse grit, a medium grit, a fine grit, or a very fine grit. In an aspect, the abrasive device 104 and/or the abrasive layer 112 of the abrasive device 104 has a grit of between about 6 to about 1,000, including between about 6 and about 24, between about 30 and about 60, between about 70 and about 180, and between about 220 and about 1,000.

[0037] In an aspect, the abrasive device 104 and/or the abrasive layer 112 of the abrasive device 104 can be replaceable (i.e., interchangeable with a new abrasive device 104 and/or abrasive layer 112). As shown in FIG. 1, the low-friction sanding assembly 100 comprises an abrasive belt feeding mechanism 122 that is configured to feed at least a second portion of the abrasive device 104 to the first surface 108 of the sanding pad 102. In embodiments, the abrasive belt feeding mechanism 122 comprises a motor and gear box 124 connected to a feed roller 126. The feed roller 126 can be in contact with the abrasive device 104 such that when the motor and gear box 124 are energized, the roller 126 rotates the abrasive device 104 thereby exchanging a used portion of the abrasive device 104 with a fresh portion of the abrasive device 104.

[0038] In embodiments, the constant-force assembly 106 of the sanding assembly 100 contacts a second surface (surface 114 shown in FIG. 2) of the sanding pad 102 and is configured to maintain a target beveling force between the abrasive device 104 and an edge of a part to be sanded (e.g., edges 154, 156 of part 152 shown in FIG. 4). In embodiments, the beveling force applied by the constant-force assembly 106 is between about 0.1 lbs. and 5.0 lbs., including from about 0.5 lbs. to about 1.0 lbs. [0039] In embodiments, the constant-force assembly 106 is configured to maintain a constant beveling force between an exposed portion 116 of the abrasive device 104 and an edge of an associated part (e.g., edges 154, 156 of part 152 shown in FIG. 4). In an aspect, the constant-force assembly 106 minimizes variations in the applied beveling force such that the target beveling force is constant within less than about ±0.5 lbs., including within less than about ±0.25 lbs., within less than about ±0.1 lbs., within less than about ±0.05 lbs., or within less than about ±0.01 lbs.

[0040] Accordingly, in embodiments, when the sanding pad 102 and the abrasive device 104 of the sanding assembly 100 are presented to an edge of a part (e.g., part 152 shown in FIG. 4) while the part 152 is being rotated, the constant-force assembly 106 applies a consistent target beveling force on a portion of the part 152 despite variations in the position, size, and/or orientation of the part 152.

[0041] With reference to FIG. 2, a cross-section of the low-friction sanding assembly 100 is illustrated, which further shows the interior of a constant-force assembly 106 according to aspects of the present disclosure. In embodiments, the constant-force assembly 106 comprises one or more guiding elements 118 and an actuator 120 that contact or are otherwise connected to the sanding pad 102.

[0042] In embodiments, the one or more guiding elements 118 of the constant-force assembly 106 are configured to guide the sanding pad 102 along a portion of the part to be sanded. In an aspect, the guiding elements 118 are low-friction guiding elements 118. In embodiments, each of the one or more guiding elements 118 comprises a guiding shaft 128 that contacts the sanding pad 102 and is disposed within a low-friction bearing 130. In an aspect, the low-friction bearings 130 are air bushings, including but not limited to, a porous air bushing and/or a porous graphite air bushing. The low-friction bearings create a thin film of pressurized air where the guide shafts 128 ride.

[0043] As shown in FIG. 2, the constant-force assembly 106 comprises a housing 132 that contains at least a portion of the guiding elements 118 and/or the actuator 120. In embodiments, the housing 132 comprises bore holes where the guiding elements 118 are disposed. In an aspect, the bore holes that hold the guiding elements 118 are parallel or machined to be parallel within at least a 0.0005-inch margin of error.

[0044] With reference to FIG. 3, another cross-section of the sanding assembly 100 is illustrated, which further shows the interior of an actuator 120 of a constant-force assembly 106 according to aspects of the present disclosure. In an aspect, the actuator 120 is a low- friction actuator that creates less than about 0.6 lbs. of friction during operation. In embodiments, the actuator 120 comprises a low-friction pneumatic cylinder 136 and a graphite piston 138 disposed within the cylinder 136. In embodiments, the pneumatic cylinder 136 is made from glass. In an aspect, the actuator 120 can comprise an electromagnetic actuator, including but not limited to, a non-commutated DC linear actuator (sometimes referred to as a “voice coil”).

[0045] In an aspect of the present disclosure, the actuator 120 operates both in the direction of the part (i.e., the working direction W) and away from the working direction. In embodiments, the actuator 120 comprises a chamber 140 opposite the working direction W that has a constant air pressure applied to it. Put another way, the actuator 120 can be configured to act as a pneumatic counterweight to compensate for the weight of the sanding pad 102 according to aspects of the present disclosure. Further, the actuator 120 can be configured to create a preload force in the constant-force assembly 106, which improves the dynamic response of the sanding assembly 100.

[0046] In embodiments, the actuator 120 also comprises a joint 142 (e.g., a universal joint or the like) between the cylinder rod 144 and the sanding pad 102. That is, the rod 144 of the actuator 120 is operatively connected to the surface 114 of the sanding pad 102 by the universal joint 142. In an aspect, the joint 142 decouples any moments of force created by misalignment of the sanding assembly 102 and/or components thereof. Put another way, the universal joint 142 ensures that only axial forces are transmitted to the sanding pad 102.

[0047] Also provided herein are low-friction sanding (e.g., beveling) machines 150. With reference to FIG. 4 and FIG. 5, the low-friction sanding machine 150 is a low-friction edge beveling machine 150 comprising at least a first low-friction sanding assembly 100 that is configured to be presented to an associated part 152 to be sanded. In embodiments, the edge beveling machine 150 can comprise two or more low-friction sanding assemblies 100 that simultaneously sand, grind, and/or otherwise bevel two or more portions of the part 152. As shown in FIG. 4, the edge beveling machine 150 comprises two low-friction sanding assemblies 100 configured to simultaneously bevel two edges 154, 156 of the part 152.

[0048] In embodiments, each of the one or more sanding assemblies 100 can be secured to a backing plate 158. As shown in FIG. 5, each the housing 132 of the constant-force assembly 106 can be secured to the backing plate 158. In embodiments, the one or more sanding assemblies 100 are then connected to one or more adjustable arms 160 of the edge beveling machine 150 via a corresponding backing plate 158. In embodiments, the adjustable arms 160 can be adjusted to accommodate different size parts (taller or shorter, wider or thinner, etc.).

[0049] In an aspect, the one or more adjustable arms 160 of the edge beveling machine 150 are configured to present the sanding pad 102 of a corresponding sanding assembly 100 to an edge 154, 156 of a part 152 to be sanded. In an aspect, the sanding pad 102 can be presented at a target beveling angle to produce a bevel on the edges 154, 156 of the part 152 at the same angle. For example, as shown in FIG. 4, the sanding assemblies 100 are mounted on the adjustable arms 160 at a 45° angle in order to produce a bevel at the same angle. In an aspect, the beveling angle can be from about 5° to about 85° relative to a face 164 of the part 152 (e.g., relative to an adjacent horizontal face 164 of the part 152 to be sanded), including from about 10° to about 80°, from about 20° to about 70°, from about 30° to about 60°, from about 40° to about 50°, and any combination of endpoints thereof.

[0050] In embodiments, the low-friction sanding machine 150 further comprises a rotating support 162 for mounting the part 152 to be sanded. In an aspect, the rotating support 162 is configured to rotate the part 152 at a predetermined rate in order to sand, grind, and/or otherwise bevel a portion of the part 152. That is, in embodiments, the abrasive devices 104 of the sanding assemblies 100 remain stationary while the part 152 rotates against the abrasive devices 104 to cause the sanding, grinding, and/or beveling effect.

[0051] With reference to FIGS. 6A and 6B, a part 152 having a beveled edge 154 produced in accordance with the present disclosure is shown. As seen, the part 152 is a cylindrical ceramic honeycomb body with at least a top edge 154 having a 45° edge bevel that is about 21.491 mil (i.e., about 0.546 mm) in length. According to aspects of the present disclosure, the bevel length is controlled by number of revolutions of the part 152, the force applied by the constant-force assembly 106, and the abrasive grit size of the abrasive device 104. In embodiments, the bevel length is less than about 10 mm, including less than about 1 mm or less than about 0.5 mm.

[0052] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

[0053] The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” [0054] The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements can optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified.

[0055] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also comprising more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” [0056] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily comprising at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements can optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

[0057] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that comprise more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0058] In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively.

[0059] Other implementations are within the scope of the following claims and other claims to which the applicant can be entitled.

[0060] While various examples have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the examples described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific examples described herein. It is, therefore, to be understood that the foregoing examples are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, examples can be practiced otherwise than as specifically described and claimed. Examples of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.