Note: Descriptions are shown in the official language in which they were submitted.
SAMPLE CUTTER
TECHNICAL FIELD
[0001] The present application generally concerns cutting devices for removing
samples. The disclosures herein more specifically concern cutting devices
employing a
supported or guided rotating sawblade.
BACKGROUND
[0002] Material testing is important to ensure the mechanical integrity of
various pieces
of equipment subject to harsh operating conditions and to maintain proper
safety margins for
continued use of the equipment. Such testing frequently requires removal of
surface and/or
subsurface samples of materials such as the metals comprising such equipment.
Samples of
sufficient size to complete standard material testing techniques are acquired
according to
destructive (or partially-destructive) methods whereby material is removed
from the equipment
rendering it inoperable. Because many types of equipment are compromised for
their purposes
by the material removed (in terms of, e.g., structural integrity, safety
factors, loss of
impermeability to fluid), such testing requires downtime and substantial
repairs or
decommissioning of the equipment.
[0003] In an example, pressure vessels and storage tanks degrade over time.
Depending on the materials stored therein, environmental conditions,
maintenance and usage
cycles, and many other variables, such equipment may remain serviceable for
decades, but can
potentially become unsafe much sooner. While the internal and external
surfaces can provide
some indication of serviceability, deeper samples taken from the inside of the
container are
typically required to fully assess its structural integrity, e.g., tensile
strength and fracture
toughness. Existing techniques capable of removing adequate samples typically
require at least
temporary decommissioning of the pressure vessel, removal of a section of its
walls, then
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extensive weld repair to restore the removed section if the vessel is to be
brought back to service
after testing is complete. Such processes are labor-intensive, expensive,
slow, and cause
significant downtime and waste.
[0004] Many other types of equipment constructed of metals or other materials
are also
unable to be tested without substantial disruption to their operation and in
turn the operation of
entities employing such equipment.
SUMMARY
[0005] In an embodiment, a sample cutter includes a blade having a cutting
edge and a
base block defining a blade channel having a variable portion of the blade
therein, wherein the
blade channel includes a pair of blade openings that open at a saw end of the
base block such that
a variable cutting portion of the blade extends beyond the base block
traversing a cutting arc.
The sample cutter further includes an internal blade guide, an external blade
guide, the external
blade guide with the internal blade guide defining a portion of the blade
channel toward the saw
end of the base block, and an internal blade guide extension of the internal
blade guide, wherein
the internal blade guide extension is configured to flex based on alignment of
the blade channel,
a kerf of a workpiece, and the blade. The sample cutter further comprises a
drive assembly
supported on the base block, the drive assembly engaging the blade to move
during a cutting
operation.
[0006] In another embodiment a sample cutter comprises a blade having a
cutting edge
defining a cutting direction and a base block enclosing a portion of the blade
with a remainder of
the blade extending outward of the base block to form a cutting arc, wherein
the base block is
pivotally mounted. The sample cutter also comprises an internal blade guide
and an internal
blade guide extension attached to the internal blade guide, wherein the
internal blade guide
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extension is configured to deflect based on alignment of a blade channel, a
kerf of a workpiece,
and the blade.
[0007] In still another embodiment a method comprises providing a sample
cutter. The
sample cutter includes a base block having a saw end and a drive end, a saw
pressure plate
disposed within the base block toward the drive end of the base block, and an
internal blade
guide disposed toward the saw end of the base block. The method further
comprises rotating the
blade within the base block and internal blade guide, at least a portion of
the blade extends
beyond the saw end of the base block; and moving at least the portion of the
blade extending
beyond the saw end of the base block through a sample cutting path including
at least a portion
of a workpiece.
[0008] Various aspects will become apparent to those skilled in the art from
the
following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIGS. 1A and 1B illustrate views of an example sample cutting
apparatus;
[0010] FIG. 2A illustrates an exploded view of an example sample cutter;
[0011] FIG. 2B illustrates a composite view of an example sample cutter;
[0012] FIG. 3A illustrates an exploded view of an example saw pressure plate
for use
with a sample cutter;
[0013] FIG. 3B shows an alternative exploded view of an example saw pressure
plate
for use with a sample cutter;
[0014] FIG. 4 illustrates an exploded view of an example saw drive wheel for
use with
a sample cutter;
[0015] FIG. 5 illustrates an alternative exploded view of an example sample
cutter;
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[0016] FIGS. 6A, 6B, 6C, and 6D illustrate views of an alternative example
drive
mechanism for a sample cutter;
[0017] FIG. 7 illustrates an example endplate for a displacement assembly used
in
conjunction with a sample cutter;
[0018] FIG. 8 illustrates an exploded view of an example gearbox for a
displacement
assembly used in conjunction with a sample cutter;
[0019] FIG. 9 illustrates an exploded view of an example positioning assembly
for use
with a sample cutter;
[0020] FIG. 10 illustrates an exploded view of an example travel guide for use
with a
displacement assembly and sample cutter;
[0021] FIGS 11A, 11B, 11C, and 11D illustrate views of an example sample
cutting
apparatus cutting through a cutting path on a workpiece;
[0022] FIGS 12A and 12B illustrate views of example samples and sample areas
in a
workpiece;
[0023] FIG. 13 illustrates a view of an alternative internal blade guide for a
sample
cutter; and
[0024] FIG. 14 illustrates an alternative view of a sample cutting apparatus
cutting
through a cutting path on a workpiece.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0025] Aspects of disclosures herein generally concern a sample cutter that
provides a
band-like blade (which can be, e.g., a continuous blade) having an unsupported
portion that
traverses a semi-circular arc length to remove samples from equipment by
passing through a
portion of the equipment to remove surface and subsurface samples of
sufficient size to perform
mechanical tests. The samples can be removed in a non-detrimental manner and
with minimal
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disruption to equipment operation. The traversing blade used in conjunction
with the sample
cutter is supported using design features of the sample cutter to provide
appropriate stiffness to
the cutting portion of the blade when first contacting or while sweeping
through the sample area.
Aspects herein further concern positioning assemblies and displacement
assemblies providing
controlled degrees of freedom to the sample cutter during installation,
cutting, or removal.
Additional aspects herein concern methodologies for removing material testing
samples from
equipment.
[0026] The improvements over blades which cannot pass through a subsurface can
be
appreciated through relating earlier sampling techniques to a scoop. Because
the scoop can only
fit a finite volume of material, and such material cannot pass through the
scoop to permit larger-
dimension cuts, earlier samples are limited by the size of the scoop, and do
not remove samples
appropriate for completing all relevant material testing.
[0027] The meaning of various terms herein will be apparent from the drawings
and
their use. However, for avoidance of confusion, an "obround blade" or similar
terminology can
refer to a blade having a cutting edge or teeth, which can (but need not, in
all embodiments) be
oriented parallel to the axis about which it traverses or rotates. An obround
blade is closed to
form a continuous loop for rotation. In this regard, an obround blade can
include, but is not
limited to, blades used with band saws. "Coupling" generally refers to
interaction and some
capability to work in tandem. Mechanical coupling places two components in
contact, either
directly or through intervening hardware. Where elements are "removably
coupled," they are
connected by attachment means which facilitate installation or
removal/decoupling while
avoiding destruction or deformation of either component being attached.
"Operative coupling"
or "communication" (e.g., fluid communication, electrical communication)
refers to components
working together, even if such components are not in physical contact (though
they may be in
physical contact). This also alludes to "electrical coupling," where by two
components can
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transmit electricity or signals between one another. For like-numbered
elements, a "prime"
number (e.g., 09 and 09') can be used to indicate an element that may be
identical or may modify
the component as needed to accommodate changes in an alternative embodiment or
different
application.
[0028] FIGS. 1A and 1B illustrate views of a sample cutter apparatus 100.
Sample
cutter apparatus 100 generally includes a cutting assembly 200, positioning
assembly 300, and
displacement assembly 400. According to an example, cutting assembly 200
pivots on
positioning assembly 300 to engage the material from which a sample is taken,
the cutting
assembly 200 may then be moved by displacement assembly 400 while engaged with
the
material to elongate the cutting area within the material and then pivoted
again by the positioning
assembly 300 to terminate the cut and exit the material. FIGS. 1A and 1B
provide non-limiting
context for the sample cutter apparatus 100 described hereafter in terms of
its movement and
employment and will be discussed in further detail below.
[0029] Cutting assembly 200 includes a blade 210 or other cutting element
having an
unsupported section to cut a material sample suitable for testing. In the
examples shown, blade
210 may include an elongate blade, which may be flexible, such as a band saw
blade. It will be
understood, that other cutting elements may be employed in cutting assembly
200 as well. With
reference to the examples shown in the accompanying figures, a flexible band
saw blade can be
blade 210, which can take the shape of an obround blade when manufactured or
when installed.
The blade is rotationally driven to perform its cutting operation. Rotational
force from a motor
may be delivered to the blade in a number of manners including drive wheel
with pressure plate
as shown. To ensure that the blade substantially maintains a desired arc or
other contour for
cutting the sample, guides are provided to maintain stiffness of the blade
and/or assist the blade
in maintaining the desired shape as will be described in more detail below.
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[0030] FIG. 2A illustrates an exploded view of cutting assembly 200, and FIG.
2B
illustrates a fully assembled cutting assembly exhibiting an unsupported semi-
circular portion of
the blade 210. FIG. 3A illustrates an exploded view of saw pressure plate 230
for use with
cutting assembly 200 and FIG. 4 illustrates an exploded view of a drive wheel
220 for use with
sample cutting assembly 200. FIG. 5 illustrates an alternative exploded view
of sample cutting
assembly 200 with internal blade guide 254 removed. FIG. 13 illustrates an
alternative internal
blade guide 1354 described later herein.
[0031] Cutting assembly 200 may include a sample cutter base 250, saw pressure
plate
230, saw drive wheel 220, and internal blade guide 254. Sample cutter base 250
includes base
block 252 having drive end 251 and saw end 259. Drive end 251 is the portion
of base block 252
distal to the workpiece when sample cutting assembly 200 is in operation. Saw
end 259 is the
portion of base block 252 from which a saw blade can extend when installed.
Base block 252
includes saw pressure plate 230 disposed within base block 252 toward drive
end 251. Toward
saw end 259, base block 252 defines external blade guide 256, and disposed at
least partially
therebetween is removable internal blade guide 254. Saw pressure plate 230,
external blade
guide 256, and internal blade guide 254 define the contours through which a
saw blade can be
installed and move, and support or constrain such saw blade to ensure
sufficient stiffness in
unconstrained portions (e.g., cutting portion of the saw when in operation) to
prevent deflection,
deformation, or other loss of cutting effectiveness.
[0032] In the embodiment illustrated, saw pressure plate 230 can include
pressure plate
hub 232, pressure plate caps 234 and 234', swivel plate(s) 237, and bearing(s)
236 (and similar
components varied based on opposing geometry). In such embodiments pressure
plate hub 232
and pressure plate caps 234 and 234', swivel plate(s) 237, and bearing(s) 236
define pressure
surface 238 from which contact pressure is distributed to a portion of the
blade in an effort to
generate the required frictional force between the blade and drive wheel tire
to propel the blade
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during sample removal. One or more such components can comprise a pressure
device of the
apparatus. In further embodiments such as that illustrated, saw pressure plate
can include one or
more pressure bearing(s) 236 which facilitate unobstructed rotation of an
installed saw blade. In
alternative embodiments more or fewer pressure bearings can be included in saw
pressure plate
230, to include none at all. Bearing surface(s) 235' (shown in Fig. 3B as an
alternative to swivel
plate assemblies 235 of Fig. 3A including bearings) can define the pressure
surface 238. Bearing
surface(s) 235' can include bearings or rollers in embodiments. However,
bearing surface(s)
235' can also provide functionality without bearings or rollers. In further
alternative or
complementary embodiments, saw pressure plate may be coupled with saw blade
release 240
which can be toggled to secure or unsecure an installed saw blade for
installation or removal.
Additionally, saw pressure plate 230 guides and externally supports an
installed saw blade to
prevent it from displacing or buckling when loads are applied during cutting
at saw end 259. At
swivel plate(s) 237 and bearing(s) 236, with other hardware, can be combined
to form swivel
plate assemblies 235. Swivel plate assemblies 235 can utilize spring forces
(mechanical,
pneumatic, or hydraulic) to transfer the load applied to the pressure plate to
the saw blade. Their
swiveling action assures self-alignment and can in embodiments assist with
distribution of
applied forces.
[0033] In specific embodiments such as that illustrated, internal blade guide
254 can be
coupled with additional components such as movable blade guide 258. Movable
blade guide 258
is attached to internal blade guide 254 using movable blade guide plate 260.
Movable blade
guide 258 can be a flexible element comprised of one or more of, e.g., foam,
rubber, plastic,
spring metals, or other appropriate materials which will deflect opposite the
cutting direction
during operation. In alternative or complementary embodiments, movable blade
guide 258 can
be a rigid, pivotable member 1358 (e.g. rigid and pinned with movable blade
guide hardware
1320, which can but need not be a pinned arrangement, or rigid and pivotable
by other methods).
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Movable blade guide 258 can be solid or skeletonized, and formed of the same
or a different
material than other components. In embodiments, movable blade guide 258 can be
formed of
two or more materials, which can be rigid and/or flexible. Movable blade guide
258 provides
support against inward or lateral collapse (e.g., folding or deflection into
internal blade guide 254
when radial or tangential force components are applied from the external
circumference of the
blade toward the internal circumference, such as when an installed blade
initially contacts a
workpiece for cutting or reaction forces on the blade during cutting). Movable
blade guide 258
can also limit vibration in the unsupported portion of a blade prior to entry
in the workpiece.
However, once the blade begins cutting, movable blade guide 258 bends or
deflects opposite the
direction of cut to permit the sample being cut to pass through the inner
portion of the
unsupported blade without disruption or significant resistance. Collapse of
the blade during this
time is unlikely as the channel being cut and partially-cut material serve to
prevent unwanted
flexion of the blade. After cutting is complete and sample material removed
from inside of the
obround cutting blade, movable blade guide 258 may restore itself to its
original position as
illustrated, or not.
[0034] Turning to FIG. 13, in further alternative or complementary
embodiments,
alternative internal blade guide assembly 1300 can include an internal blade
guide 1354 with
internal blade guide extension(s) 1310. Internal blade guide extension(s) 1310
allow for the
reduction (or subsequent increase) in the lateral width of the internal blade
guide 1354 near saw
end 259 (e.g., providing support to a portion of the blade while providing a
variable dimension)
to rectify any offset between the blade channel (e.g., the channel established
between the
external blade guide 256 and internal blade guide 1354 or internal blade guide
254) and the
established kerf in the workpiece as the sample cutter base 250 approaches a
position normal to
the workpiece. This reduces the likelihood of certain problems during
operation such as the
binding of the blade before or during cutting. Internal blade guide
extension(s) 1310 can be
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formed of various materials including spring steel or others. Internal blade
guide extension(s)
1310 can be rigid, flexible, or a combination of both when formed of one or
more materials or
supported in different manners. Internal blade guide extension(s) 1310 may be
cantilever
spring(s) as illustrated in FIG 13. In an embodiment, a spring may be used to
connect one or
more internal blade guide extensions 1310 to allow deflection of a internal
blade guide extension
1310 that is rigid. In such embodiments a spring (or other resilient and
compressible or
stretchable member such as a gasket) can be used at a pin or placed between
internal blade guide
extension(s) 1310 and another surface with which they interact to allow for
motion while biasing
toward a particular deflection. For example, a spring or resilient member can
be disposed
between internal blade guide 1354 and internal blade guide extension 1310,
providing an
outward bias but capable of deflecting inward. In further alternative or
complementary
embodiments, the internal blade guide 1354 can be pivotable near the saw end
and spring
supported. During cutting and as the distance between base block and workpiece
closes, the
stiffness of the blade may prevent movement (e.g., jogging) that allows the
blade to maintain the
kerf and/or channel. Flex provided by the internal blade guide extension(s)
1310 permits
controlled movement facilitating maintenance of the kerf/channel by the blade.
[0035] Where pivotable, internal blade guide 1354 can be biased toward a
position
(e.g., resists deflection or returns to alignment with internal blade guide
assembly 1300 in the
absence of a force causing pivoting) using springs in hardware 1320 or other
components.
[0036] In further embodiments, rather than using a flexible or movable
internal blade
guide extension 1310, one or more parts of internal blade guide 1354 (or 254)
can be arranged to
move themselves. For example, the ends disposed toward the cutting portion of
a blade can be
pinned or hinged and, in combination with resilient members (e.g., springs,
elastic), can be
configured to rotate or deflect inward to provide similar effect. In
embodiments like those
shown using internal blade guide 254, the cross member can be excluded or
formed of a material
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configured to deform if it is connected to any deflecting or moving portion of
internal blade
guide 254. In embodiments, the cross member may be a resilient member that can
be
compressed or stretched to provide bias to maintain movable portions of
internal blade guide 254
in their default positions.
[0037] As with other elements of apparatuses disclosed here, alternatives can
be
combined in any combination without departing from the scope or spirit of the
innovation. For
example, movable blade guide 258 may be flexible but pinned using hardware
1320 or similar
apparatuses. Internal blade guide 1354 can be utilized with apparatus 100.
These are non-
exhaustive examples, and those of ordinary skill in the art will appreciate
other combinations of
alternatives on review of this disclosure.
[0038] Internal guide cap 262 can also be placed over at least a portion of
internal blade
guide 254 and external blade guide 256 in embodiments, providing another
constraint against
deflection or inadvertent removal of an installed saw blade by preventing the
blade's movement
in a direction orthogonal to support provided by external blade guide 256 and
internal blade
guide 254. External blade guide 256 (and, in embodiments alternative or
complementary to that
depicted) can also retain one or more blade bearings 268 for encouraging
smooth travel of an
installed obround blade.
[0039] External blade guide 256 can have an external guide surface, and
internal blade
guide 254 can have an internal guide surface, which are arranged with respect
to one another to
define at least a portion of a blade channel. These surfaces can be surfaces
the blade travels,
translates, and/or rotates between, adjacent to, in contact with, or spaced
apart from. The blade
channel can receive at least a portion of the blade, and the portion can be
variable (e.g., as the
blade translates or rotates, the portion of the blade in a given channel space
will vary).
[0040] In embodiments such as that depicted, saw drive wheel 220 is disposed
within
base block 252 between saw pressure plate 230 and internal blade guide 254. As
illustrated, saw
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drive wheel 220 can include drive wheel 222, drive wheel tire 224, drive wheel
caps 226 and
226', and drive shaft 228. Drive shaft 228 can couple with drive gearing 264
and/or drive
bearing 266. Drive gearing 264 is configured to communicate mechanically with
a saw drive
motor. In alternative embodiments, other techniques may be utilized for
employing a saw
constrained by internal and external guides and/or a pressure plate.
[0041] In further embodiments, the use of external blade guide 256 and
internal blade
guide 254 in combination with saw drive wheel 220 and saw pressure plate 230
can ensure
stiffness is maintained on the blade to further resist buckling or excessive
distortion.
[0042] In further embodiments, sample cutter base 250 include a drive mounting
portion configured to mount a saw drive motor in a manner facilitating
actuation of an installed
saw blade.
[0043] Obround saw blade 210 appropriate for use with a sample cutting
assembly 200
is shown in, e.g., FIG. 2. Obround saw blade 210 can have a circumference (or
length), a width
(e.g., the larger axial dimension typically parallel to the axis or axes about
which the blade
rotates), and a thickness (e.g., the width of the cutting edge or rear non-
cutting edge). Obround
saw blade 210 can be a round saw blade or other appropriate blade which cuts
through rotation
about an axis or axes typically parallel to the width of the blade, e.g., the
axial direction. As
illustrated, obround saw blade 210 includes at least teeth 212 and band 214.
In at least one
embodiment, teeth 212 can be realized using, or replaced or supplemented by a
grit (e.g., carbide
grit, diamond grit) or other cutting surface.
[0044] In embodiments, obround saw blade 210 is disposed partially within base
block
252, and in at least partial contact with saw pressure plate 230 near drive
end 251 of the base
block. Further, at least a portion of an external circumference of obround saw
blade 210 is
contained within external blade guide 256, and at least a portion of an
internal circumference of
obround saw blade 210 is disposed around internal blade guide 254 (or internal
blade guide
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1354, with or without internal blade guide extension 1310, or other
alternatives disclosed herein),
with a cutting portion of obround saw blade 210 extending beyond saw end 259
of the base
block. Obround saw blade 210 can be any appropriate blade of any appropriate
material and is
sized or configured to extend beyond saw end 259 such that samples of the
desired size can be
cut when obround saw blade 210 is in contact or adjacent to the above-
described elements.
Obround saw blade 210 is exchangeable and replaceable with new or different
saw blades of
sufficient length for installation.
[0045] Obround saw blade 210 (and any other blades in alternative embodiments)
abide
particular material and geometric parameters to prevent buckling of the blade
during operation.
Such parameters include bend radius, the length of the unsupported arc of
blade, blade thickness,
blade width, blade elastic modulus, blade material hardness, et cetera. Such
parameters are
interdependent and adjusting one parameter may require adjustment to other
parameters if
buckling or other deformation is to be avoided under a given load.
[0046] Turning to FIGS. 6A to 6D, an alternative drive mechanism 220' for use
with
alternative blade 210' is illustrated. Drive mechanism 220' includes drive
shaft 228' and
employs cogs 221' matched to blade apertures 211' of blade 210' to ensure non-
slipping
movement of blade 210'. Blade 210' also includes teeth 212' and band 214', and
may (but need
not) be obround when manufactured or installed. While FIGS. 6A to 6D show an
alternative
embodiment to the tire embodiment depicted elsewhere herein, those of skill in
the art will
appreciate still other techniques for driving an obround saw blade, and these
disclosures are
intended to convey concepts for saw drive rather than exhaustive or exclusive
listings of
embodiments.
[0047] Regardless of which drive mechanism is employed ¨220, 220', or
alternatives ¨
a motor such as saw drive motor 290 can be coupled with sample cutting
assembly 200 to
provide power to the drive mechanism. In alternative or complementary
embodiments other
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arrangements can be developed through gears, linkages, et cetera, to permit
other power sources
(e.g., various motors or positioning elements herein) to move an obround saw
blade installed to
sample cutting assembly 200.
[0048] Turning to techniques for employing the sample cutter, FIGS. 1A, 1B,
and 7 to
illustrate other components of sample cutter apparatus 100 used therewith.
While sample
cutting assembly 200 can be coupled to or used with these elements, its
discussion herein is
limited in view of the details provided above. Nonetheless, all aspects set
forth above and others
appreciated through discussion hereafter apply equally throughout this
specification.
[0049] Sample cutter apparatus 100 can include sample cutting assembly 200 for
use
with positioning assembly 300 and displacement assembly 400. Positioning
assembly 300 can
be coupled with the sample cutting assembly 200, and is used to raise, lower,
or rotate sample
cutting assembly 200 with respect to a workpiece. In this regard, positioning
assembly 300 is
configured to move sample cutting assembly 200 toward or away from the
workpiece, and may
rotate sample cutting assembly 200 to permit the blade to encounter the
workpiece at an angle
appropriate for cutting then guide the blade through the sample path.
[0050] As illustrated, positioning assembly 300 includes slide assembly 310
for moving
sample cutting assembly 200 toward or away from the workpiece. This and other
elements of
positioning assembly 300 can be positioned by, e.g., positioning element 350
or other
components. Positioning assembly 300 can also include at least one spindle
assembly 330
mechanically coupled to positioning assembly 300. Spindle assembly 330 is
configured to rotate
the positioning assembly 300 in relation to a surface of a workpiece, and can
include spindle gear
332, spindle 334, pivot stop 336 (e.g., to aid in spindle gear 332 to
displacement rack 450 gear
tooth alignment), and spindle plate 338. Alternative or complementary rotation
components can
be used independently or in combination with spindle assembly 330.
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[0051] Positioning element 350 can be a precision lead screw or other
positioner and
may be manually operated or automated. In embodiments, positioning element 350
can be a
positioning drive motor. While positioning element 350 and other drive
mechanisms herein may
be described as motored, manually-operated, or moved according to various
other techniques, it
is understood in view of this disclosure that such aspects may be
interchangeable without
departing from the scope or spirit of the innovation.
[0052] Displacement assembly 400 is mechanically coupled with at least
positioning
assembly 300. Displacement assembly 400 is configured to move positioning
assembly 300 in
relation to a surface of a workpiece. Displacement assembly can be defined by
fixed
components at the ends of its length, which can include endplate 418 and
gearbox 410. Gearbox
410 can further include gearings 414 and gearbox caps 412 and 412'.
Displacement drive motor
440 and air valves 442 can be coupled to at least gearbox 410. In an
embodiment, air valves 442
can be used to receive compressed air for air drive functions complementary or
alternative to
displacement drive motor 440. Further coupled to one or both of gearbox 410
and endplate 418,
attachment assembly 444 is configured to removably couple the sample cutting
apparatus with a
workpiece. In embodiments, attachment assembly 444 includes magnetic elements.
In
alternative or complementary embodiments, suction cup devices can be used
(e.g., with non-
ferromagnetic materials). In still further complementary or alternative
embodiments, attachment
assembly 444 can include a magnetic creeper (or other translatable attachment
sub-assembly) to
move the cutter's positioning in relation to the workpiece remotely.
[0053] Displacement assembly 400 can further include travel guide 430
comprising
travel guide block 432 and linear bearing 434 to assist with displacement or
stabilizing of sample
cutting assembly 200 and/or positioning assembly 300. Displacement assembly
400 can further
include displacement rack 450, threaded displacement rod 452, hardened shaft
454, cross brace
456, and/or other elements for traversing various components about a
workpiece. Generally
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speaking, the dimensions of displacement rack 450, threaded displacement rod
452, and
hardened shaft 454 define a maximum sample length, and so can be designed or
adjusted to
achieve various sample lengths.
[0054] While displacement assembly 400 shows the ability to translate its
coupled
components along a linear path, alternative or complementary embodiments can
include a
displacement assembly capable of moving other assemblies in additional
directions. In this
manner, multiple samples may be taken from a single installation, and more
accurate sample
locations can be cut without repositioning the entire apparatus. Further, if
coupled with the
capability to rotate the saw about the axis orthogonal to the workpiece
surface (e.g., another
degree of rotational freedom for positioning assembly 300), samples can also
be cut in various
directions without repositioning displacement assembly 400 and coupled
structures.
[0055] Sample cutter apparatus 100 can also include a controller 500 in one or
more of
the assemblies (e.g., sample cutting assembly 200, positioning assembly 300,
displacement
assembly 400) or at a remote location where the assemblies include wired or
wireless ports for
receiving signals. Controller 500 can at least control operation of the motors
to displace,
position, and/or rotate the assemblies, and/or cause blade 210 to spin or
cease spinning to enable
cutting. Controller 500 may be automated, manual, or a combination thereof,
and may also send
and receive data related to at least operation of sample cutter apparatus 100.
In an embodiment,
sensed resistance to cutting can be used to indicate a mismatch between blade
type and material,
or excess wear in a blade. Warnings and alarms can be provided when motors,
connected drive
shafts, or other components stall, slip, fail, et cetera. In alternative or
complementary
embodiments, unexpected ease of cutting can be used to discern over-cuts which
cut entirely
through a workpiece rather than removing a sub-surface sample that does not
compromise the
workpiece's structural integrity. Controller 500 can permit reversal of an
undesired cut to avoid
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full removal of the sample and ease repairs. Other logic can be employed for
various alternative
control and data gathering functions.
[0056] FIGS. 11A to 11D illustrate an example process using a sample cutting
apparatus as disclosed herein. FIG. 11A shows sample cutter apparatus 100
attached to
workpiece 900 and arranged to cut a sample defined by cutting path 910.
[0057] As the obround blade cuts into the surface of workpiece 900, the
positioning
assembly and sample cutting assembly are rotated and level after reaching the
cut depth, shown
in FIG. 11B. In this regard, the obround blade (e.g., 210) has a maximum depth
defined by the
vertical distance (measured in a direction e.g., typically parallel to the
plane defined by the face
of internal guide cap 262) between the blade's bottom-most edges (e.g.,
extending beyond saw
end 259) and the bottom-most edges of the sample cutting assembly (e.g., 200,
and more
particularly external blade guide 256, internal blade guide 254, and internal
guide cap 262, the
bottom-most portions of the assembly). The saw is arranged such that the cut
depth facilitates
clearance or at least friction still permitting movement between the workpiece
and non-cutting
portions of the sample cutting assembly. Saw blades (and, in some embodiments,
movable blade
guides) can be configured and provided to facilitate different cut depths. In
embodiments,
appropriate saw blade length can be determined as a function of saw blade
material or stiffness to
ensure the blade does not collapse, bend, or otherwise compromise the cut or
apparatus during
operation.
[0058] FIG. 11C shows the blade at the cutting depth nearing the end of the
cut length
for the desired sample size. In FIG. 11D, the positioning assembly rotates the
sample cutter out
of the workpiece to free the sample and sample cutting apparatus. The sample
can then be
removed and sample cutting apparatus detached and removed or installed at
another location for
additional sample cutting.
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[0059] In an alternative embodiment, the rotating obround blade can be used to
cut only
a portion of a sample having a uniform cross-section, with tapering edges of a
sample (e.g.,
where the sample height varies or tapers along the sample length) cut by
another mechanism. In
such embodiments, an alternative cutter (excluding, in comparison to
embodiments shown
above, e.g., a pressure plate or portions thereof, a movable blade guide, some
or all of an internal
or external blade guide, spindles or other rotating mechanisms) may be
employed. For
embodiments in which the rotating blade only sweeps through portions of
uniform cross-section,
loads on the blade will not be borne in or from directions, or in magnitudes,
as would be
encountered during the blade's initial bite into the workpiece and during
rotation through the
tapered ends of the workpiece before proceeding through the substantially
linear cutting path. In
this regard, scoop or other angled or rotating cutters can be used to begin
the cut into the
workpiece for sample extraction and the rotating obround blade can be arranged
within an
existing cut for its use in the process.
[0060] FIGS. 12A and 12B illustrate various views of a sample 920 cut from
workpiece
900. Sample 920 has a sample height 922, a sample length 924, and a sample
width 926,
respectively corresponding to a cut depth 912, cut length 914, and cut width
916. These
dimensions, dependent on saw blade length, can be cut large enough to permit
any type of
material testing to determine the serviceability or condition of workpiece
900. While workpiece
900 is shown as a linear block for ease of explanation, it is understood that
workpiece 900 may
be a curved pressure vessel wall, asymmetrical or non-planar piece, et cetera.
[0061] A method reflecting the techniques illustrated in, e.g., FIGS. 11A to
11D can
include providing a sample cutter including a base block configured to couple
with a positioning
assembly, the base block having a saw end and a drive end, a saw pressure
plate disposed within
the base block toward the drive end of the base block, an external blade guide
disposed toward
the saw end of the base block, and an internal blade guide disposed toward the
saw end of the
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base block and at least partially within the external blade guide. Thereafter
the method can
include supporting at least a portion of a circumference of an obround blade
in the sample cutter,
then rotating the obround blade within the base block, external blade guide,
and internal blade
guide, at least a portion of the sawblade extends beyond the saw end of the
base block. The
method can further include moving at least the portion of the sawblade
extending beyond the saw
end of the base block through a sample cutting path including at least a
portion of a workpiece.
[0062] In various embodiments methods can further include providing a
displacement
assembly configured to move the sample cutting assembly in relation to a
surface of the
workpiece. In alternative or complementary embodiments, methods can further
include
attaching the displacement assembly to the workpiece. In additional
embodiments, methods can
include providing a positioning assembly mechanically coupled with the sample
cutter, the
positioning assembly configured to move the sample cutter toward or away from
a workpiece. In
still further embodiments, methods can include rotating the base block in
relation to a surface of
the workpiece.
[0063] FIG. 14 shows another example of a cutting technique using an apparatus
including internal blade guide 1354 and internal blade guide extension(s)
1310. As base block
252' approaches a position normal to workpiece 900' during a cut the kerf
established in
workpiece 900' may be slightly different than the nominal curvature of the
blade when outside
workpiece 900'. As the blade begins to cut into workpiece 900', the portion of
the blade in
workpiece 900' may stretch and cause narrowing toward the midline of base
block 252'. The
narrowing causes an offset between the established kerf in workpiece 900' and
the nominal
position of the blade in the blade channel. A fixed or rigid internal blade
guide would not allow
any reduction in offset and since there is insufficient distance between the
bottom of base block
252' and the top of workpiece 900' to allow for lateral displacement of the
blade due to its
inherent stiffness. In such circumstances, the blade may wedge then bind. To
rectify this
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problem, internal blade guide extensions 1310 are provided with internal blade
guide 1354 (or
other internal blade guides disclosed herein). Internal blade guide extensions
1310 are stiff
enough to resist lateral loads due to cutting operation, but flexible enough
to allow for sufficient
displacement under the high wedging loads caused by the offset as base block
252' reaches a
normal position with respect to workpiece 900'. An example design may employ
one or more
cantilever leaf springs that are in direct contact with the inside surface of
the blade.
Alternatively, as discussed above, a portion of internal blade guide 1354 (or
254) can be
configured to deflect. This allows the blade (dashed line) to maintain the
kerf (lines outside
dashed line).
[0064] In the specification and claims, reference is made to a number of terms
described hereafter. The singular forms "a," "an," and "the" include plural
referents unless the
context clearly dictates otherwise. Approximating language, as used herein
throughout the
specification and claims, may be applied to modify a quantitative
representation that could
permissibly vary without resulting in a change in the basic function to which
it is related.
Accordingly, a value modified by a term such as "about" is not to be limited
to the precise value
specified. In some instances, the approximating language may correspond to the
precision of an
instrument for measuring the value. Moreover, unless specifically stated
otherwise, a use of the
terms "first," "second," etc., do not denote an order or importance, but
rather the terms "first,"
"second," etc., are used to distinguish one element from another.
[0065] As used herein, the terms "may," "may be," "can," and/or "can be"
indicate a
possibility of an occurrence within a set of circumstances; a possession of a
specified property,
characteristic or function; and/or qualify another verb by expressing one or
more of an ability,
capability, or possibility associated with the qualified verb. Accordingly,
usage of "may" and
"may be" indicates that a modified term is apparently appropriate, capable, or
suitable for an
indicated capacity, function, or usage, while considering that in some
circumstances the modified
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105669.000003
term may sometimes not be appropriate, capable, or suitable. For example, in
some
circumstances an event or capacity can be expected, while in other
circumstances the event or
capacity cannot occur ¨ this distinction is captured by the terms "may" and
"may be."
[0066] As utilized herein, the term "or" is intended to mean an inclusive "or"
rather
than an exclusive "or." That is, unless specified otherwise, or clear from the
context, the phrase
"X employs A or B" is intended to mean any of the natural inclusive
permutations. That is, the
phrase "X employs A or B" is satisfied by any of the following instances: X
employs A; X
employs B; or X employs both A and B. In addition, the articles "a" and "an"
as used in this
application and the appended claims should generally be construed to mean "one
or more" unless
specified otherwise or clear from the context to be directed to a singular
form.
[0067] To the extent that the term "includes" is used in either the detailed
description or
the claims, such term is intended to be inclusive in a manner similar to the
term "comprising" as
"comprising" is interpreted when employed as a transitional word in a claim.
[0068] Although the present disclosure and its advantages have been described
in
detail, it should be understood that various changes, substitutions and
alterations can be made
herein without departing from the spirit and scope of the disclosure as
defined by the appended
claims. Moreover, the scope of the present application is not intended to be
limited to the
particular embodiments of the process, machine, manufacture, composition of
matter, means,
methods and steps described in the specification. As one of ordinary skill in
the art will readily
appreciate from the disclosure, processes, machines, manufacture, compositions
of matter,
means, methods, or steps, presently existing or later to be developed that
perform substantially
the same function or achieve substantially the same result as the
corresponding embodiments
described herein may be utilized according to the present disclosure.
Accordingly, the appended
claims are intended to include within their scope such processes, machines,
manufacture,
compositions of matter, means, methods, or steps.
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