EP1250980A1 - Welding electrode polishing machine - Google Patents
Welding electrode polishing machine Download PDFInfo
- Publication number
- EP1250980A1 EP1250980A1 EP00971807A EP00971807A EP1250980A1 EP 1250980 A1 EP1250980 A1 EP 1250980A1 EP 00971807 A EP00971807 A EP 00971807A EP 00971807 A EP00971807 A EP 00971807A EP 1250980 A1 EP1250980 A1 EP 1250980A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- grinding
- electrode
- disk
- welding electrodes
- holder
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B47/00—Drives or gearings; Equipment therefor
- B24B47/02—Drives or gearings; Equipment therefor for performing a reciprocating movement of carriages or work- tables
- B24B47/04—Drives or gearings; Equipment therefor for performing a reciprocating movement of carriages or work- tables by mechanical gearing only
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B19/00—Single-purpose machines or devices for particular grinding operations not covered by any other main group
- B24B19/16—Single-purpose machines or devices for particular grinding operations not covered by any other main group for grinding sharp-pointed workpieces, e.g. needles, pens, fish hooks, tweezers or record player styli
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B55/00—Safety devices for grinding or polishing machines; Accessories fitted to grinding or polishing machines for keeping tools or parts of the machine in good working condition
- B24B55/06—Dust extraction equipment on grinding or polishing machines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
- B24D7/14—Zonally-graded wheels; Composite wheels comprising different abrasives
Definitions
- the present invention relates to improvements in a grinding machine to grind to a specific shape the end portion of welding electrodes of tungsten, molybdenum, chromium and the like for use in such welding techniques as TIG welding and plasma arc welding.
- the shape of the end portion of a welding electrode for use in TIG welding is dependent on factors such as electric current density, current distribution and cooling effects etc. in the welding area and affects the efficiency of welding work and the welding quality. Therefore, the end portion of the welding electrode is finished to a proper shape, for example, a sharp cone or two-step cut formed of a tapered area and a flat area (a so-called "truncated conic shape") depending on the material and thickness of the base metal, welding conditions and other factors.
- the external surface of the tip of the welding electrode finished to a specific form is polished to a high degree of smoothness.
- the hemispherical tip 12 for example, has a diameter D of 0.5 to 2.0 mm and tapers to a hemispherical tip A 0 with a radius (R) of 0.08 to 0.1 mm. It is desirable that the external surface of the hemispherical tip Ab is more smoothly ground than the tapered section A1 of the electrode. If the external surface of the hemispherical tip A 0 is finished to a mirror surface or a specular surface, the directivity and stability of the arc will be substantially improved.
- the end portion of the electrode A is usually ground by a special electrode grinding machine.
- a special electrode grinding machine Such as the machine shown in FIG. 13 and disclosed in unexamined Japanese utility model application No. 4-60386 and unexamined Japanese patent application No. 7-276211.
- the following two methods are widely adopted.
- a grinding disk B 1 which has a relatively large grain size (#170, for example) is fixed on motor drive shaft M1 is used to grind the end portion of electrode A to a specific form.
- the grinding disk B1 is replaced with a grinding disk B2 which has a finer grain size (#500, for example).
- the tip of the electrode is finely ground.
- the second method two grinding machines are used. One is equipped with grinding disk B1 which has a large grain size and another with grinding disk B2 which has a fine grain size. The end portion of the electrode is shaped to a specific form with the grinding disk B1, and is then finely ground or polished with the grinding disk B2.
- the letter C indicates a housing
- the letter M a grinder motor
- the letter D a grinding disk clamping screw
- the letter E a dust cover
- the letter F an electrode guide
- the second method requires two electrode grinding machines, which represents poor economy and results in increased maintenance costs.
- the axial position of electrode A is often dislocated when grinding disk B1 with a large grain size is replaced with grinding disk B2 with a fine grain size. Accordingly it is difficult to maintain the concentricity of electrode A. As a result, it takes a substantial period of time to grind and polish the tip to a mirror surface and furthermore, the form of the tip itself can change in an unintended way.
- a particular object of the present invention to provide a grinding machine for welding electrodes as defined in claim 1 which comprises a box-like housing 1, a grinder motor 2 fixed within the housing 1, a disk-like grinding disk 3 fixed on a motor drive shaft 2a of a grinder motor 2 and provided with a grinding area 3A, a swing plate 4 provided on the housing 1 above the grinding disk 3 and supported movably in the direction of the axis ⁇ of a motor drive shaft 2a, a cylindrical holder guide 6 turnably supported on the swing plate 4 in a vertical orientation with a downward portion protruding above the grinding disk 3 in the housing 1, an electrode holder 7 removably fitted into holder guide 6 and removably clamping an electrode A with its tip in contact with the grinding area 3A of the grinding disk 3, an electrode turning motor 8 fixed within the housing 1 to turn the holder guide 6 with the electrode holder 7 held therein, and a swing plate moving mechanism 9 for moving the swing plate 4 by a specific distance 1 along the axi
- the invention of claim 2 is the grinding machine for welding electrodes as defined in claim 1 wherein the grinding area 3A of the grinding disk 3 is formed of a first grinding part 3a made of coarse grains and a second grinding part 3b made of fine grains.
- the invention of claim 3 is the grinding machine for welding electrodes as defined in claim 1 wherein the grinding area 3A of the grinding disk 3 is formed of - on a front side of the disk - a first grinding part 3a for grinding an end portion of the electrode A to form a cone and - on an outer circumferential side of the disk - a second grinding part 3b provided with a V-shaped grinding groove 3b' for grinding a tip A 0 of the electrode to a mirror surface.
- the invention of claim 4 is the grinding machine for welding electrodes as defined in claim 1 wherein the grinding area 3A of the grinding disk 3 is so constituted that the first grinding part 3a for forming the end portion of the electrode A in the form of a cone and the second grinding part 3b for polishing the tip A 0 of the conically formed end portion of the electrode to a mirror surface are provided on the front side of the disk.
- the invention of claim 5 is the grinding machine for welding electrodes as defined in claim 4 wherein the first grinding part 3a is on an inner portion of the disk in the radial direction and on the front side thereof in the thickness direction and the second grinding part 3b is provided on an outer portion of the disk in the radial direction and on said front side thereof but recessed in the thickness direction.
- the invention of claim 6 is the grinding machine for welding electrodes as defined in claim 5 wherein the inclination angle ⁇ 1 of a longitudinally inclined surface 3a 1 defining the first grinding part 3a is the same as that of a longitudinally inclined surface 3b 1 defining the second grinding part 3b, wherein the inclination angle ⁇ 2 of a transversely inclined surface 3a 2 defining the first grinding part 3a is the same as that of a transversely inclined surface 3b 2 defining the second grinding part 3b, and wherein the radius R of an arc-like joint between the longitudinally inclined surface 3a 1 and the transversely inclined surface 3a 2 of the first grinding part 3a is identical to that of an arc-like joint between a longitudinally inclined surface 3b 1 and a transversely inclined surface 3b 2 of the second grinding part 3b.
- the invention of claim 7 is the grinding machine for welding electrodes as defined in claim 1 wherein the grinding area 3A of the grinding disk 3 is integrally formed of grains with a medium grain size.
- the invention of claim 8 is the grinding machine for welding electrodes as defined in claim 7 wherein the grinding area 3A of the grinding disk 3 comprises a longitudinally inclined surface 3a 1 to form the end portion of the electrode A into the shape of a cone, a transversely inclined surface 3a 2 to discharge grinding dust and a curved surface 3a 3 to polish the tip A 0 of the electrode A to a mirror surface.
- the invention of claim 9 is the grinding machine for welding electrodes as defined in claim 1 wherein the grinding area 3A of the grinding disk 3 is formed on both sides of a base of the grinding disk 3 symmetrically.
- the invention of claim 10 is the grinding machine for welding electrodes as defined in claim 1 wherein one end of the swing plate 4 is pivotably fixed on an upper wall of the housing (1) in such a way that the other end can be moved in the direction of the axis ⁇ of the motor drive shaft 2a.
- the invention of claim 11 is the grinding machine for welding electrodes as defined in claim 1 wherein the electrode holder 7 comprises a cylindrical chuck guide 7a, a collet chuck 7b to be inserted into an end of said chuck guide 7a and a cylindrical chuck screw 7c inserted into the chuck guide 7a from an upper side thereof, with the tip portion screwed into the collet chuck 7b.
- the invention of claim 12 is the grinding machine for welding electrodes as defined in claim 11 wherein a spacer 16 with a specific thickness h is placed on the chuck guide 7a of the electrode holder 7 so that the tip A 0 of the electrode A is positioned within a grinding groove 3b' of the second grinding part 3b.
- the invention of claim 13 is the grinding machine for welding electrodes as defined in claim 1 wherein the holder guide 6 with the electrode holder 7 held therein is turned by the electrode turning motor 8 via a round rubber belt 15.
- the invention of claim 14 is the grinding machine for welding electrodes as defined in claim 1 wherein the swing plate moving mechanism 9 comprises a moving handle 9a and a worm gear 9b which is turned by said moving handle 9a and engages with a thread 4c provided on the swing plate 4.
- the invention of claim 15 is the grinding machine for welding electrodes as defined in claim 14 wherein the distance 1 for which the electrode holder 7 is moved by the swing plate moving mechanism 9 is indicated by a dial gauge 10 having a drive body 10a which is interlocked with a gauge stopper 4b provided on the swing plate 4.
- FIG. 1 is a plan view of a grinding machine for welding electrodes of the present invention.
- FIG. 2 is a side elevation thereof.
- FIG. 3 is a front elevation thereof.
- FIG. 4 is a schematic vertical, sectional elevation thereof.
- FIG. 5 is a schematic vertical front elevation.
- the grinding machine for welding electrodes of the present invention comprises a box-shaped housing 1, a grinder motor 2 placed inside the housing 1, a grinding disk 3 which is turned at a high speed by the grinder motor 2, a swing plate 4 provided in a front part of an upper wall of the housing 1, a cylindrical bushing 5 fixed vertically in the centre of the swing plate 4, a cylindrical holder guide 6 rotatably inserted into the bushing 5, an electrode holder 7 removably inserted into the holder guide 6 in a vertical position, an electrode turning motor 8 for turning the electrode holder 7 via holder guide 6, a swing plate moving mechanism 9 to move one side of the swing plate 4 supporting the electrode holder 7, a dial gauge 10 to indicate the extent of movement of the electrode holder 7 held by the swing plate 4, and an electric control unit 11 to control the drive of the grinder motor 2 and electrode turning motor 8, etc.
- the housing 1 is provided with a grinding extent setting gauge 12 to set the extent of grinding the electrode, a dresser (not shown) to clean the grinding surface of the grinding disk 3 and others.
- the housing 1 is made in the form of a box and is formed of a housing main body 1a made of steel plate or a plastic material with an opening on a front side and a dust cover 1b made of a transparent plastic material that covers the opening of the front side.
- the housing 1 includes a clamp 1c to fix the dust cover 1b a grip 1d and bushings 1e.
- housing main body 1a The interior of housing main body 1a is partitioned by a partition plate 1f.
- a dust case 1g is removably placed in a lower part of a front compartment.
- a support member 1h for fixing the motors 2, 8 is provided in the rear compartment of the housing main body 1a.
- a hole 1i with a long opening into which are inserted the cylindrical bushing 5, the holder guide 6 etc. as will be described below. Furthermore, a port 1j to store a grinding extent setting gauge 12 is provided in a one side of the rear compartment.
- the grinder motor 2 is fixed horizontally on a lower side of the support member 1h with a motor drive shaft 2a extending through the partition plate 1f and protruding up into a space above the dust case 1g of the housing main body 1a.
- a grinding disk holder 2b is fixed on the motor drive shaft 2a. Furthermore, the grinding disk 3 is removably clamped on the grinding disk holder 2b by a grinding disk clamping screw 13.
- the grinder motor 2 used in this embodiment is a 100-watt single phase alternating current motor for 100 volts, AC, 50/60 Hz. If a switch 14 for grinder motors is turned on, the motor will turn for a specific time preset by a electric control unit 11 and will be automatically stopped by a timer switch.
- the grinding disk 3 is made in the form of a disk approximately 60 mm in diameter and about 8.2 mm in thickness as shown in FIG. 6.
- the grinding disk 3 is fitted over a stepped front end of the grinding disk holder 2b and fixed by said grinding disk clamping screw 13.
- the grinding disk 3 is formed of a first grinding part 3a made of relatively coarse diamond abrasive grains and a second grinding part 3b made of relatively fine diamond abrasive grains.
- the first grinding part 3a has a longitudinally inclined surface 3a 1 with an inclination having an angle ⁇ 1 of approximately 10° with respect to a line perpendicular to the axis ⁇ of the motor drive shaft 2a and a transversely inclined surface 3a 2 with an inclination angle ⁇ 2 of approximately 20° with respect to said axis ⁇ .
- the intersection point P of the two surfaces is curved with a radius of about 0.08 mm.
- the second grinding part 3b of the grinding disk 3 is formed on an outer circumferential surface of the first grinding part 3a and has a longitudinally inclined surface 3b 1 continuous with the longitudinally inclined surface 3a 1 of the first grinding part 3a.
- On the outer circumferential surface of the second grinding part 3b there is provided a V-shaped grinding groove 3b' with an opening angle ⁇ 3 of approximately 10° with a line perpendicular to the axis ⁇ and a depth of about 1.2 mm.
- the first grinding part 3a is formed of relatively coarse diamond abrasive grains about #170 in grain size
- the second grinding part 3b is formed of relatively fine diamond abrasive grains about #500 in grain size.
- the shortest distance 1 between the line passing the intersection point P, perpendicular to the axis ⁇ and the centre of the grinding groove 3b' is set at about 2.5 mm and the shortest distance h between the line passing the intersection point P, parallel to the axis ⁇ and the bottom of the grinding groove 3b'is set at about 3.8 mm (for an electrode A 2.0 mm in outside diameter).
- the swing plate 4 is provided on the front end of the upper side of the housing main body 1a and one end thereof is pivotably held at one point by a support axis 4a so that the swing plate 4 can move in the directions of the arrows as shown in FIG. 1.
- Another end of the swing plate 4 has a gauge stopper 4b thereon which is brought into contact with the tip of a drive body 10a of the dial gauge 10.
- the other end of the swing plate 4 has a screw thread 4c that engages with a worm gear 9b of the swing plate moving mechanism 9, which will be described below.
- a bushing fixing hole 4d is formed in the centre of the swing plate 4.
- a short cylindrical bushing 5 is inserted to support rotatably said electrode holder 7. And the top of the cylindrical bushing 5 is fixed to the swing plate 4.
- the cylindrical holder guide 6 is rotatably inserted from above. That is, the holder guide 6 is turnably and movably supported in a vertical position with an annulus 6a at the top engaging with an upper end surface of the bushing 5.
- the holder guide 6 is to fix removably the electrode holder 7 and is cylindrical in shape as shown in FIG. 4. Said holder guide 6 is rotatably supported in a vertical position on the swing plate 4 via the bushing 5 as mentioned above, and in this holder guide 6, the electrode holder 7 is removably inserted and fixed.
- a slave pulley 6b is formed in a lower part of the holder guide 6.
- a rubber belt 15 connects the slave pulley 6b and a drive pulley 17 disposed on a drive shaft 8a of the electrode turning motor 8.
- the electrode holder 7 is to hold removably and clamp an electrode A in such a way that a tip of the electrode is in contact with the first grinding part 3a of the grinding disk 3.
- the electrode chuck unit 7 comprises, as shown in FIG. 7, a cylindrical chuck guide 7a to be removably inserted into the holder guide 6, a collet chuck 7b inserted into an end portion of the chuck guide 7a and a chuck screw 7c inserted from an upper side of the chuck guide 7a and screwed on and engaged with the collet chuck 7b. If the electrode A is passed through the collet chuck 7b and the chuck screw 7c is tightened up, the collet chuck 7b will squeeze and hold and clamp the electrode A.
- a number of different collet chucks 7b can be made with different respective inside diameters of electrode insertion hole.
- the grinding machine can accept electrodes A with diameters between 1.0 mm to 2.6 mm.
- the chuck guide 7a is so made that a spacer 16 can be removably fitted on the chuck guide 7a as shown in FIG. 7.
- the spacer 16 is used when the tip A 0 of electrode A is ground to a mirror surface by the second grinding part 3b after an end portion of electrode A is formed.
- the electrode turning motor 8 is mounted in a rear portion within the housing main body 1a and is put on a lower side of the support member 1h.
- Said drive pulley 17 is fixed on said drive shaft 8a of the electrode turning motor 8. And an endless rubber belt 15 is placed around the drive pulley 17 and the slave pulley 6b of the holder guide 6.
- the holder guide 6 is driven via said endless rubber belt 15, which, in turn, drives the electrode holder 7 removably clamped in the holder guide 6 and the electrode A fixed therein.
- the swing plate moving mechanism 9 comprises a moving handle 9a, the worm gear 9b to be turned by said moving handle 9a, and the thread 4c at the end of the swing plate 4 engaging said worm gear 9b and others. If the moving handle 9a is turned, the worm gear 9b moves the swing plate 4 in the directions of the arrows using the support axis 4a as a fulcrum.
- the electrode holder 7 fixed on the swing plate 4 moves together with the result that the tip of electrode A moves in the direction of the axis ⁇ of the motor drive shaft 2a.
- the extent to which the swing plate 4 is moved by turning the moving handle 9a is shown on the dial gauge 10. That is, as said drive body 10a that is in contact with the gauge stopper 4b on the swing plate 4 moves in the directions of the arrows, the extent of movement of the swing plate 4 is indicated on the dial gauge 10.
- dial gauge 10 itself is known and will not be explained.
- the electric control unit 11 is for controlling the operation, including startup and stopping of the grinder motor 2 and the electrode turning motor 8. If the switch 14 for grinder motor is turned on, the two motors 2, 8 will turn at a specific speed for a preset time.
- the two motors 2, 8 are switched to high speed mode with a greater number of revolutions by actuating a switchover limit switch 18, and the two motors 2, 8 turn at a specific speed for a preset time.
- Said grinding extent setting gauge 12 is used to set the protruding extent of the electrode A held by the electrode holder 7 to decide the grinding extent of electrode A.
- the grinding extent setting gauge 12 is removably stored on one side wall of the housing main body 1a.
- the grinding extent setting gauge 12 comprises, as shown in FIG. 8, a cylindrical gauge main body 12a, a nut 12b fixed on an end of the gauge main body 12a and a setting bolt 12c screwed into the nut 12b.
- the grinding extent setting gauge 12 is used in the following way. First, the electrode A is held and clamped in the electrode holder 7 with its tip portion protruding by a specific length. Then, the electrode holder 7 is inserted into the holder guide 6 and the electrode A is test-ground on the first grinding part 3a of the grinding disk 3. Then the electrode is checked to see if the end portion is ground to a perfect cone. If electrode A is ground perfectly, the electrode holder 7 with electrode A held and clamped thereon is taken out and placed in the gauge main body 12a, and the setting bolt 12c is moved to adjust the gap between the tip of the electrode A and the end of the setting bolt 12c to a specific distance, 0.5 mm, for example. Once the grinding extent setting gauge is set this way, the grinding extent of the electrode A can be adjusted and fixed simply by this gauge.
- the first step is to select a grinding disk 3 that is suitable for electrode A with regard to its diameter and the grinding shape of the end portion.
- This grinding disk 3 is placed on the motor drive shaft 2a.
- the electrode A is inserted into the collet chuck 7b of the electrode holder 7. With its tip portion protruded by a specific length (45 mm to 50 mm) from the end of the collet chuck 7b, the electrode A is slidably held by lightly tightening the chuck screw 7c.
- the electrode holder 7 with said electrode A held therein is inserted into the gauge main body 12a of the grinding extent setting gauge 12 and, with the tip of the electrode A in contact with the setting bolt 12c, the electrode A is pushed back though the collet chuck 7b. And when the electrode holder 7 is fully fitted into the gauge main body 12a, the chuck screw 7c is tightened up to clamp the electrode A. Thus, the protruding extent and the grinding extent of electrode A are now set. It is assumed that the electrode A has been test-ground as mentioned above and that the position of the setting bolt 12c of the grinding extent setting gauge 12 has been adjusted properly.
- the electrode holder 7 is inserted into the holder guide 6 to place the tip of the electrode A on the first grinding part 3a of the grinding disk 3, and then the switch 14 is turned on.
- the electrode A While the electrode A turns, its tip is kept in contact with the first grinding part 3a of the grinding disk 3 and gradually ground. As the electrode A is ground, the electrode holder 7 slides down through the holder guide 6 under its own weight, and the end portion of electrode A is automatically ground in the form of a cone. When the electrode holder 7 slides down by a certain distance, a knob of the chuck guide 7a comes to rest on an upper end of the holder guide 6, preventing the electrode holder 7 from sliding down any further.
- the timer automatically switches off the motors 2, 8 with the conical form grinding completed.
- the electrode holder 7 is pulled out of the holder guide 6 and the spacer 16 is put on the electrode holder 7.
- the moving handle 9a of the swing plate moving mechanism 9 is turned to move the position of the axis of the holder guide 6 inwardly (i.e. in the direction of the centre of the housing 1) by a specific distance 1.
- the tip of electrode A held by the electrode holder 7 comes just above the second grinding part 3b of the grinding disk 3 when the electrode holder 7 is placed in the holder guide 6.
- the spacer 16 is put on the chuck guide 7a of the electrode holder 7. And the electrode holder 7 with the spacer 16 put thereon is placed in the holder guide 6.
- the thickness of the spacer 16 is set to dimension h mentioned above.
- the switchover limit switch 18 is actuated to automatically switch the two motors 2, 8 to a high speed. And the hemispherical tip of the electrode A is finished to a mirror surface with great efficiency.
- FIG. 9 shows a second embodiment of the grinding disk 3.
- the grinding disk 3 of the second embodiment is made in the form of a disk about 60 mm in diameter and about 8.2 mm in thickness.
- the grinding disk 3 is placed on the stepped part of the front end portion of the grinding disk holder 2b and clamped to the grinding disk holder 2b by tightening up the clamping screw 13.
- the grinding disk 3 has a first grinding part 3a made of relative coarse grains of about #170 and a second grinding part 3b made of relatively fine grains of about #500.
- the first grinding part 3a and the second grinding part 3b are formed as step formations on the front side of the disk.
- the first grinding part 3a is provided on the front side of the disk in an inner portion in the radial direction.
- the first grinding part 3a has a longitudinally inclined surface 3a 1 having an inclination with an angle ⁇ 1 of approximately 10° with respect to a line perpendicular to the axis ⁇ of the motor drive shaft 2a, and a transversely inclined surface 3a 2 having an inclination angle ⁇ 2 of approximately 20° with respect to the axis ⁇ .
- a joint P between the two inclined surfaces is curved in the form of an arc with a radius R of approximately 0.08 mm.
- the second grinding part 3b is provided outside the first grinding part 3a in the radial direction and on the front side but recessed in the thickness direction, and has a longitudinally inclined surface 3b 1 having an inclination angle ⁇ 1 of approximately 10° with the line perpendicular to the axis ⁇ of the motor drive shaft 2a and a transversely inclined surface 3b 2 having an inclination with an angle ⁇ 1 of approximately 20° with respect to the axis ⁇ .
- An arc-shaped joint Q between the two inclined surfaces is curved with a radius R of approximately 0.08 mm.
- the distance 1 in the thickness direction of the disk (that is, the drive shaft direction of the grinder motor) is about 2.5 mm between the arc-like joint P of the first grinding part 3a and the arc-like joint Q of the second grinding part 3b, and the distance h in the radial direction of the disk is set at some 3.8 mm (for electrode A with an outside diameter of 2.0 mm).
- the first grinding part 3a and the second grinding part 3b are identical in terms of their angles ⁇ 1 , ⁇ 2 and radius R. Needless to say, they may be made different from each other.
- this second embodiment is identical to the first embodiment in terms of distance 1 and distance h. Again, needless to say, a different distance 1 and a different distance h may be adopted in the second embodiment.
- the second grinding part 3b is open on the front side, and does not have a V-shaped groove as in the first embodiment. Therefore, the second grinding part 3b is hardly clogged. That substantially saves labour needed for maintenance and care of the grinding disk 3.
- FIG. 10 shows a third embodiment of the grinding disk 3.
- the grinding disk 3 is some 60 mm in diameter and about 8.2 mm in thickness and is integrally formed of diamond abrasive grains (abrasive material) of a medium grain size (#350, for example) between coarse grains (#170, for example) and fine grains (#500, for example).
- the grinding disk 3 is put on the stepped part of the grinding disk holder 2b and clamped by the grinding disk clamping screw 13.
- the grinding disk 3 is provided with a grinding area 3A to grind the end portion of the electrode A.
- Said grinding area 3A is formed in a shape corresponding to the finished shape of the end portion of the electrode A as shown in FIG. 12.
- the electrode holder 7 is inserted into the holder guide 6 and, with the tip of electrode A in contact with the grinding area 3A of the first grinding part 3a, the switch for the grinder motor 14 is turned on, as in the case of the first embodiment.
- the grinding disk 3 is turned about the axis ⁇ by the grinder motor 2, and at the same time the electrode A is turned around the axis ⁇ a by the electrode turning motor 8.
- the electrode A turns and the end portion thereof is ground on the grinding area 3A of the grinding disk 3 with which the electrode A is in contact.
- the electrode holder 7 moves down in the holder guide 6 under its own weight.
- the end portion of the electrode A is automatically shaped to a cone by the longitudinally inclined surface 3a 1 of the grinding disk 3.
- the tip of the electrode A is ground and finished to a hemispherical mirror surface by the curved surface 3a 3 of the grinding disk 3.
- the electrode A is ground and finished that way. It is so arranged that the axis ⁇ a of the electrode A extends along a line perpendicular to the axis ⁇ of the motor drive shaft 2a, and the grinding area 3A of the grinding disk 3 has a form corresponding to the finished shape of the electrode A. Furthermore, the grinding disk 3 is turned by the grinder motor 2, and at the same time the electrode A is turned by the electrode turning motor 8.
- the timer switch automatically stops the motors 2, 8, and the grinding is finished.
- the electrode holder 7 is pulled out of the holder guide 6, and electrode A is taken out of the electrode holder 7. Then electrode A is obtained with the end section in the form of a conic taper A 1 and with the tip end A 0 finished to a hemispherical, mirror surface as shown in FIG. 12.
- the moving handle 9a of the swing plate moving mechanism 9 is turned to move the position of the axis of the holder guide 6 along the axis ⁇ of the motor drive shaft 2a by a specific distance while watching the dial gauge 10 so as to adjust the contact between the electrode A and the grinding disk 3.
- the grinding area 3A of the grinding disk 3 is provided with a longitudinally inclined surface 3a 1 , and the curved surface 3a 3 is matched to the finished shape of the electrode A as shown in FIG. 12.
- the present invention is not limited to that.
- the grinding area 3A may be provided with a two-stepped inclination contour, that is, two longitudinally inclined surfaces.
- FIG. 11 shows a fourth embodiment of the grinding disk 3.
- This grinding disk 3 has two grinding areas 3A of the third embodiment symmetrically formed on both sides of a base 3c so that each of the two grinding areas 3A can be used in turn.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
- Electrical Discharge Machining, Electrochemical Machining, And Combined Machining (AREA)
Abstract
A grinding machine for welding electrodes which grinds the end portion of an
electrode to a final form and finishes the tip end of the electrode to a mirror surface. All
the grinding work can be done by this grinding machine alone and one grinding disk.
The grinding machine for welding electrodes comprises a housing 1, a grinder
motor 2, a grinding disk 3, a swing plate 4, a holder guide 6, a electrode holder 7, an
electrode turning motor 8 and swing plate moving mechanism 9. And it is so arranged
that the axis a of electrode A extends along the line perpendicular to the axis of a
motor drive shaft 2a and that a first grinding part 3a of the grinding disk 3 is so formed
to conform to the finishing contour of electrode A. Furthermore, the grinding disk 3 is
turned by the grinder motor 2 and at the same time electrode A is turned by the
electrode turning motor 8.
Description
- The present invention relates to improvements in a grinding machine to grind to a specific shape the end portion of welding electrodes of tungsten, molybdenum, chromium and the like for use in such welding techniques as TIG welding and plasma arc welding.
- The shape of the end portion of a welding electrode for use in TIG welding is dependent on factors such as electric current density, current distribution and cooling effects etc. in the welding area and affects the efficiency of welding work and the welding quality. Therefore, the end portion of the welding electrode is finished to a proper shape, for example, a sharp cone or two-step cut formed of a tapered area and a flat area (a so-called "truncated conic shape") depending on the material and thickness of the base metal, welding conditions and other factors. The external surface of the tip of the welding electrode finished to a specific form is polished to a high degree of smoothness. Tungsten electrode A for TIG welding as shown in FIG. 12, for example, has a diameter D of 0.5 to 2.0 mm and tapers to a hemispherical tip A0 with a radius (R) of 0.08 to 0.1 mm. It is desirable that the external surface of the hemispherical tip Ab is more smoothly ground than the tapered section A1 of the electrode. If the external surface of the hemispherical tip A0 is finished to a mirror surface or a specular surface, the directivity and stability of the arc will be substantially improved.
- To this end the end portion of the electrode A is usually ground by a special electrode grinding machine. Such as the machine shown in FIG. 13 and disclosed in unexamined Japanese utility model application No. 4-60386 and unexamined Japanese patent application No. 7-276211. The following two methods are widely adopted. In a first method (hereinafter referred to as "the first method"), a
grinding disk B 1 which has a relatively large grain size (#170, for example) is fixed on motor drive shaft M1 is used to grind the end portion of electrode A to a specific form. Then, the grinding disk B1 is replaced with a grinding disk B2 which has a finer grain size (#500, for example). By use of the grinding disk B2, the tip of the electrode is finely ground. In a second method (hereinafter referred to as "the second method"), two grinding machines are used. One is equipped with grinding disk B1 which has a large grain size and another with grinding disk B2 which has a fine grain size. The end portion of the electrode is shaped to a specific form with the grinding disk B1, and is then finely ground or polished with the grinding disk B2. - In FIG. 13, the letter C indicates a housing, the letter M a grinder motor, the letter D a grinding disk clamping screw, the letter E a dust cover, and the letter F an electrode guide.
- However, the problem with the first method is that two grinding disks B1, B2 have to be changed for each stage of the grinding work and therefore the grinding process is inefficient and slow.
- The second method requires two electrode grinding machines, which represents poor economy and results in increased maintenance costs.
- Furthermore, the axial position of electrode A is often dislocated when grinding disk B1 with a large grain size is replaced with grinding disk B2 with a fine grain size. Accordingly it is difficult to maintain the concentricity of electrode A. As a result, it takes a substantial period of time to grind and polish the tip to a mirror surface and furthermore, the form of the tip itself can change in an unintended way.
- In view of the problems encountered in grinding the end portion of a welding electrode by grinding machines disclosed in the prior art which are; (1) when working with a grinding machine using a grinding disk with a large grain size and another with a fine grain size, it is troublesome to replace one grinding disk with another each time, and it is difficult to maintain the concentricity of the electrode when the grinding disks are changed, and (2) the use of two grinding machines is expensive and it is difficult to maintain the concentricity of the electrode; it is a general object of the present invention to provide a grinding machine for welding electrodes by which the end portion of even a very short electrode can be ground to a specific shape efficiently by a simple procedure and only the tip is finished to a mirror surface, i.e. all the grinding work can be done by this machine alone, and not using two grinding machines.
- To solve the above-mentioned problems, a particular object of the present invention to provide a grinding machine for welding electrodes as defined in
claim 1 which comprises a box-like housing 1, agrinder motor 2 fixed within thehousing 1, a disk-like grinding disk 3 fixed on amotor drive shaft 2a of agrinder motor 2 and provided with agrinding area 3A, aswing plate 4 provided on thehousing 1 above thegrinding disk 3 and supported movably in the direction of the axis of amotor drive shaft 2a, acylindrical holder guide 6 turnably supported on theswing plate 4 in a vertical orientation with a downward portion protruding above thegrinding disk 3 in thehousing 1, anelectrode holder 7 removably fitted intoholder guide 6 and removably clamping an electrode A with its tip in contact with thegrinding area 3A of thegrinding disk 3, anelectrode turning motor 8 fixed within thehousing 1 to turn theholder guide 6 with theelectrode holder 7 held therein, and a swingplate moving mechanism 9 for moving theswing plate 4 by aspecific distance 1 along the axis of themotor drive shaft 2a. - The invention of
claim 2 is the grinding machine for welding electrodes as defined inclaim 1 wherein thegrinding area 3A of thegrinding disk 3 is formed of a first grindingpart 3a made of coarse grains and a second grindingpart 3b made of fine grains. - The invention of
claim 3 is the grinding machine for welding electrodes as defined inclaim 1 wherein thegrinding area 3A of thegrinding disk 3 is formed of - on a front side of the disk - a first grindingpart 3a for grinding an end portion of the electrode A to form a cone and - on an outer circumferential side of the disk - a second grindingpart 3b provided with a V-shaped grinding groove 3b' for grinding a tip A0 of the electrode to a mirror surface. - The invention of
claim 4 is the grinding machine for welding electrodes as defined inclaim 1 wherein thegrinding area 3A of thegrinding disk 3 is so constituted that the first grindingpart 3a for forming the end portion of the electrode A in the form of a cone and the second grindingpart 3b for polishing the tip A0 of the conically formed end portion of the electrode to a mirror surface are provided on the front side of the disk. - The invention of
claim 5 is the grinding machine for welding electrodes as defined inclaim 4 wherein thefirst grinding part 3a is on an inner portion of the disk in the radial direction and on the front side thereof in the thickness direction and the second grindingpart 3b is provided on an outer portion of the disk in the radial direction and on said front side thereof but recessed in the thickness direction. - The invention of
claim 6 is the grinding machine for welding electrodes as defined inclaim 5 wherein the inclination angle α1 of a longitudinallyinclined surface 3a1 defining thefirst grinding part 3a is the same as that of a longitudinallyinclined surface 3b1 defining the second grindingpart 3b, wherein the inclination angle α2 of a transverselyinclined surface 3a2 defining the first grindingpart 3a is the same as that of a transverselyinclined surface 3b2 defining the second grindingpart 3b, and wherein the radius R of an arc-like joint between the longitudinallyinclined surface 3a1 and the transverselyinclined surface 3a2 of thefirst grinding part 3a is identical to that of an arc-like joint between a longitudinallyinclined surface 3b1 and a transverselyinclined surface 3b2 of the second grindingpart 3b. - The invention of
claim 7 is the grinding machine for welding electrodes as defined inclaim 1 wherein thegrinding area 3A of thegrinding disk 3 is integrally formed of grains with a medium grain size. - The invention of
claim 8 is the grinding machine for welding electrodes as defined inclaim 7 wherein thegrinding area 3A of thegrinding disk 3 comprises a longitudinallyinclined surface 3a1 to form the end portion of the electrode A into the shape of a cone, a transverselyinclined surface 3a2 to discharge grinding dust and acurved surface 3a3 to polish the tip A0 of the electrode A to a mirror surface. - The invention of
claim 9 is the grinding machine for welding electrodes as defined inclaim 1 wherein thegrinding area 3A of thegrinding disk 3 is formed on both sides of a base of thegrinding disk 3 symmetrically. - The invention of
claim 10 is the grinding machine for welding electrodes as defined inclaim 1 wherein one end of theswing plate 4 is pivotably fixed on an upper wall of the housing (1) in such a way that the other end can be moved in the direction of the axis of themotor drive shaft 2a. - The invention of
claim 11 is the grinding machine for welding electrodes as defined inclaim 1 wherein theelectrode holder 7 comprises acylindrical chuck guide 7a, acollet chuck 7b to be inserted into an end of saidchuck guide 7a and acylindrical chuck screw 7c inserted into thechuck guide 7a from an upper side thereof, with the tip portion screwed into thecollet chuck 7b. - The invention of
claim 12 is the grinding machine for welding electrodes as defined inclaim 11 wherein aspacer 16 with a specific thickness h is placed on thechuck guide 7a of theelectrode holder 7 so that the tip A0 of the electrode A is positioned within agrinding groove 3b' of the second grindingpart 3b. - The invention of
claim 13 is the grinding machine for welding electrodes as defined inclaim 1 wherein theholder guide 6 with theelectrode holder 7 held therein is turned by theelectrode turning motor 8 via around rubber belt 15. - The invention of
claim 14 is the grinding machine for welding electrodes as defined inclaim 1 wherein the swingplate moving mechanism 9 comprises a movinghandle 9a and aworm gear 9b which is turned by said movinghandle 9a and engages with a thread 4c provided on theswing plate 4. - The invention of
claim 15 is the grinding machine for welding electrodes as defined inclaim 14 wherein thedistance 1 for which theelectrode holder 7 is moved by the swingplate moving mechanism 9 is indicated by adial gauge 10 having adrive body 10a which is interlocked with agauge stopper 4b provided on theswing plate 4. -
- FIG. 1 is a plan view of a grinding machine for welding electrodes in accordance with the present invention.
- FIG. 2 is a side elevation of the grinding machine for welding electrodes.
- FIG. 3 is a front elevation of the grinding machine for welding electrodes.
- FIG. 4 is a vertical, sectional side elevation of the essential part of the grinding machine for welding electrodes.
- FIG. 5 is a vertical, sectional front elevation of the essential part of the grinding machine for welding electrodes.
- FIG. 6 is a sectional view of a grinding disk.
- FIG. 7 is a sectional view of an electrode chuck body.
- FIG. 8 is an explanatory view of an electrode grinding extent setting gauge.
- FIG. 9 is a sectional view of a grinding disk for welding electrodes in accordance with a second embodiment.
- FIG. 10 is a sectional view of a grinding disk for welding electrodes according to a third embodiment.
- FIG. 11 is a sectional view of a grinding disk for welding electrodes according to a fourth embodiment.
- FIG. 12 shows an example of the form of the end portion of a tungsten electrode for TIG welding.
- FIG. 13 shows an example of the prior art grinding machine for welding electrodes.
-
-
- A
- electrode A
-
- axis of motor drive shaft
- a
- electrode axis
- A1
- tapered section of electrode
- A0
- tip end of electrode
- 1a
- case main body
- 1b
- dust cover
- 1c
- clamp
- 1d
- grip
- 1e
- bushing
- 1f
- partition plate
- 1g
- dust case
- 1h
- support component part
- 1i
- hole
- 1j
- storage port
- 2
- grinder motor
- 2a
- drive shaft
- 2b
- grinding disk holder
- 3
- grinding disk
- 3A
- grinding area
- 3a
- first grinding part
- 3b
- second grinding part
- 3a1
- longitudinally inclined surface
- 3b1
- longitudinally inclined surface
- 3a2
- transversely inclined surface
- 3b2
- transversely inclined surface
- 3b'
- grinding groove
- 3c
- base
- 4
- swing plate
- 4a
- support axis
- 4b
- gauge stopper
- 4c
- screw
- 4d
- bushing fixing hole
- 5
- cylindrical bushing
- 6
- holder guide
- 6a
- annulus
- 6b
- pulley
- 7
- electrode holder
- 7a
- chuck guide
- 7b
- collet chuck
- 7c
- check screw
- 8
- electrode turning motor
- 8a
- drive shaft
- 9
- swing plate moving mechanism
- 9a
- moving handle
- 9b
- worm gear
- 9c
- worm box
- 10
- dial gauge
- 10a
- drive body
- 11
- electric control unit
- 12
- grinding extent setting gauge
- 12a
- gauge main body
- 12b
- nut
- 12c
- setting bolt
- 13
- grinding disk clamping screw
- 14
- switch for grinder motors
- 15
- round rubber belt
- 16
- spacer
- 17
- drive pulley
- 18
- switchover limit switch
- Now, the embodiments of the present invention will be described with reference to the drawings.
- FIG. 1 is a plan view of a grinding machine for welding electrodes of the present invention. FIG. 2 is a side elevation thereof. FIG. 3 is a front elevation thereof. FIG. 4 is a schematic vertical, sectional elevation thereof. FIG. 5 is a schematic vertical front elevation.
- The grinding machine for welding electrodes of the present invention comprises a box-shaped
housing 1, agrinder motor 2 placed inside thehousing 1, agrinding disk 3 which is turned at a high speed by thegrinder motor 2, aswing plate 4 provided in a front part of an upper wall of thehousing 1, acylindrical bushing 5 fixed vertically in the centre of theswing plate 4, acylindrical holder guide 6 rotatably inserted into thebushing 5, anelectrode holder 7 removably inserted into theholder guide 6 in a vertical position, anelectrode turning motor 8 for turning theelectrode holder 7 viaholder guide 6, a swingplate moving mechanism 9 to move one side of theswing plate 4 supporting theelectrode holder 7, adial gauge 10 to indicate the extent of movement of theelectrode holder 7 held by theswing plate 4, and anelectric control unit 11 to control the drive of thegrinder motor 2 andelectrode turning motor 8, etc. In addition, thehousing 1 is provided with a grindingextent setting gauge 12 to set the extent of grinding the electrode, a dresser (not shown) to clean the grinding surface of thegrinding disk 3 and others. - The
housing 1 is made in the form of a box and is formed of a housingmain body 1a made of steel plate or a plastic material with an opening on a front side and adust cover 1b made of a transparent plastic material that covers the opening of the front side. In addition, thehousing 1 includes aclamp 1c to fix thedust cover 1b agrip 1d andbushings 1e. - The interior of housing
main body 1a is partitioned by apartition plate 1f. Adust case 1g is removably placed in a lower part of a front compartment. - Furthermore, a support member 1h for fixing the
motors main body 1a. - In the centre of the upper wall of the front compartment of the housing
main body 1a, there is provided a hole 1i with a long opening into which are inserted thecylindrical bushing 5, theholder guide 6 etc. as will be described below. Furthermore, a port 1j to store a grindingextent setting gauge 12 is provided in a one side of the rear compartment. - The
grinder motor 2 is fixed horizontally on a lower side of the support member 1h with amotor drive shaft 2a extending through thepartition plate 1f and protruding up into a space above thedust case 1g of the housingmain body 1a. - In addition, a
grinding disk holder 2b is fixed on themotor drive shaft 2a. Furthermore, thegrinding disk 3 is removably clamped on thegrinding disk holder 2b by a grindingdisk clamping screw 13. - The
grinder motor 2 used in this embodiment is a 100-watt single phase alternating current motor for 100 volts, AC, 50/60 Hz. If aswitch 14 for grinder motors is turned on, the motor will turn for a specific time preset by aelectric control unit 11 and will be automatically stopped by a timer switch. - The
grinding disk 3 is made in the form of a disk approximately 60 mm in diameter and about 8.2 mm in thickness as shown in FIG. 6. Thegrinding disk 3 is fitted over a stepped front end of thegrinding disk holder 2b and fixed by said grindingdisk clamping screw 13. - The
grinding disk 3 is formed of a firstgrinding part 3a made of relatively coarse diamond abrasive grains and a secondgrinding part 3b made of relatively fine diamond abrasive grains. The firstgrinding part 3a has a longitudinallyinclined surface 3a1 with an inclination having an angle α1 of approximately 10° with respect to a line perpendicular to the axis of themotor drive shaft 2a and a transverselyinclined surface 3a2 with an inclination angle α2 of approximately 20° with respect to said axis . The intersection point P of the two surfaces is curved with a radius of about 0.08 mm. - The second
grinding part 3b of thegrinding disk 3 is formed on an outer circumferential surface of the first grindingpart 3a and has a longitudinallyinclined surface 3b1 continuous with the longitudinally inclinedsurface 3a1 of the first grindingpart 3a. On the outer circumferential surface of the secondgrinding part 3b, there is provided a V-shaped grindinggroove 3b' with an opening angle α3 of approximately 10° with a line perpendicular to the axis and a depth of about 1.2 mm. - In the present embodiment, the first grinding
part 3a is formed of relatively coarse diamond abrasive grains about #170 in grain size, and the secondgrinding part 3b is formed of relatively fine diamond abrasive grains about #500 in grain size. - Furthermore, the
shortest distance 1 between the line passing the intersection point P, perpendicular to the axis and the centre of the grindinggroove 3b' is set at about 2.5 mm and the shortest distance h between the line passing the intersection point P, parallel to the axis and the bottom of the grinding groove 3b'is set at about 3.8 mm (for an electrode A 2.0 mm in outside diameter). - Referring to FIGS. 1 to 5, the
swing plate 4 is provided on the front end of the upper side of the housingmain body 1a and one end thereof is pivotably held at one point by asupport axis 4a so that theswing plate 4 can move in the directions of the arrows as shown in FIG. 1. - Another end of the
swing plate 4 has agauge stopper 4b thereon which is brought into contact with the tip of adrive body 10a of thedial gauge 10. - Furthermore, the other end of the
swing plate 4 has a screw thread 4c that engages with aworm gear 9b of the swingplate moving mechanism 9, which will be described below. - A
bushing fixing hole 4d is formed in the centre of theswing plate 4. In thisbushing fixing hole 4d, a shortcylindrical bushing 5 is inserted to support rotatably saidelectrode holder 7. And the top of thecylindrical bushing 5 is fixed to theswing plate 4. - In the short
cylindrical bushing 5, thecylindrical holder guide 6 is rotatably inserted from above. That is, theholder guide 6 is turnably and movably supported in a vertical position with anannulus 6a at the top engaging with an upper end surface of thebushing 5. - The
holder guide 6 is to fix removably theelectrode holder 7 and is cylindrical in shape as shown in FIG. 4. Saidholder guide 6 is rotatably supported in a vertical position on theswing plate 4 via thebushing 5 as mentioned above, and in thisholder guide 6, theelectrode holder 7 is removably inserted and fixed. - In addition, a
slave pulley 6b is formed in a lower part of theholder guide 6. Arubber belt 15 connects theslave pulley 6b and adrive pulley 17 disposed on adrive shaft 8a of theelectrode turning motor 8. - The
electrode holder 7 is to hold removably and clamp an electrode A in such a way that a tip of the electrode is in contact with the first grindingpart 3a of thegrinding disk 3. - The
electrode chuck unit 7 comprises, as shown in FIG. 7, acylindrical chuck guide 7a to be removably inserted into theholder guide 6, acollet chuck 7b inserted into an end portion of thechuck guide 7a and achuck screw 7c inserted from an upper side of thechuck guide 7a and screwed on and engaged with thecollet chuck 7b. If the electrode A is passed through thecollet chuck 7b and thechuck screw 7c is tightened up, thecollet chuck 7b will squeeze and hold and clamp the electrode A. - A number of
different collet chucks 7b can be made with different respective inside diameters of electrode insertion hole. In the present embodiment, by electing a collet chuck with an appropriate diameter of electrode insertion hole, the grinding machine can accept electrodes A with diameters between 1.0 mm to 2.6 mm. - In addition, the
chuck guide 7a is so made that aspacer 16 can be removably fitted on thechuck guide 7a as shown in FIG. 7. As will be described below, thespacer 16 is used when the tip A0 of electrode A is ground to a mirror surface by the secondgrinding part 3b after an end portion of electrode A is formed. - The
electrode turning motor 8 is mounted in a rear portion within the housingmain body 1a and is put on a lower side of the support member 1h. - Said drive
pulley 17 is fixed on saiddrive shaft 8a of theelectrode turning motor 8. And anendless rubber belt 15 is placed around thedrive pulley 17 and theslave pulley 6b of theholder guide 6. Thus, if theelectrode turning motor 8 is turned, theholder guide 6 is driven via saidendless rubber belt 15, which, in turn, drives theelectrode holder 7 removably clamped in theholder guide 6 and the electrode A fixed therein. - The swing
plate moving mechanism 9 comprises a movinghandle 9a, theworm gear 9b to be turned by said movinghandle 9a, and the thread 4c at the end of theswing plate 4 engaging saidworm gear 9b and others. If the movinghandle 9a is turned, theworm gear 9b moves theswing plate 4 in the directions of the arrows using thesupport axis 4a as a fulcrum. - If the
swing plate 4 moves in the directions of the arrows, theelectrode holder 7 fixed on theswing plate 4 moves together with the result that the tip of electrode A moves in the direction of the axis of themotor drive shaft 2a. - The extent to which the
swing plate 4 is moved by turning the movinghandle 9a is shown on thedial gauge 10. That is, as saiddrive body 10a that is in contact with thegauge stopper 4b on theswing plate 4 moves in the directions of the arrows, the extent of movement of theswing plate 4 is indicated on thedial gauge 10. - It is noted that the
dial gauge 10 itself is known and will not be explained. - The
electric control unit 11 is for controlling the operation, including startup and stopping of thegrinder motor 2 and theelectrode turning motor 8. If theswitch 14 for grinder motor is turned on, the twomotors - To grind and polish the tip of electrode A to a mirror surface using the second
grinding part 3b of thegrinding disk 3, the twomotors motors - Said grinding
extent setting gauge 12 is used to set the protruding extent of the electrode A held by theelectrode holder 7 to decide the grinding extent of electrode A. The grindingextent setting gauge 12 is removably stored on one side wall of the housingmain body 1a. - The grinding
extent setting gauge 12 comprises, as shown in FIG. 8, a cylindrical gaugemain body 12a, anut 12b fixed on an end of the gaugemain body 12a and asetting bolt 12c screwed into thenut 12b. With theelectrode holder 7 inserted into the gaugemain body 12a, the tip of electrode A is brought into contact with thesetting bolt 12c which controls the extent to which the electrode A protrudes out of theelectrode holder 7. - In this regard, the grinding
extent setting gauge 12 is used in the following way. First, the electrode A is held and clamped in theelectrode holder 7 with its tip portion protruding by a specific length. Then, theelectrode holder 7 is inserted into theholder guide 6 and the electrode A is test-ground on the first grindingpart 3a of thegrinding disk 3. Then the electrode is checked to see if the end portion is ground to a perfect cone. If electrode A is ground perfectly, theelectrode holder 7 with electrode A held and clamped thereon is taken out and placed in the gaugemain body 12a, and thesetting bolt 12c is moved to adjust the gap between the tip of the electrode A and the end of thesetting bolt 12c to a specific distance, 0.5 mm, for example. Once the grinding extent setting gauge is set this way, the grinding extent of the electrode A can be adjusted and fixed simply by this gauge. - Next, the grinding of an electrode A using the grinding machine for electrodes of the present invention will be described.
- The first step is to select a
grinding disk 3 that is suitable for electrode A with regard to its diameter and the grinding shape of the end portion. Thisgrinding disk 3 is placed on themotor drive shaft 2a. Then, the electrode A is inserted into thecollet chuck 7b of theelectrode holder 7. With its tip portion protruded by a specific length (45 mm to 50 mm) from the end of thecollet chuck 7b, the electrode A is slidably held by lightly tightening thechuck screw 7c. - The
electrode holder 7 with said electrode A held therein is inserted into the gaugemain body 12a of the grindingextent setting gauge 12 and, with the tip of the electrode A in contact with thesetting bolt 12c, the electrode A is pushed back though thecollet chuck 7b. And when theelectrode holder 7 is fully fitted into the gaugemain body 12a, thechuck screw 7c is tightened up to clamp the electrode A. Thus, the protruding extent and the grinding extent of electrode A are now set. It is assumed that the electrode A has been test-ground as mentioned above and that the position of thesetting bolt 12c of the grindingextent setting gauge 12 has been adjusted properly. - Then, the
electrode holder 7 is inserted into theholder guide 6 to place the tip of the electrode A on the first grindingpart 3a of thegrinding disk 3, and then theswitch 14 is turned on. - While the electrode A turns, its tip is kept in contact with the first grinding
part 3a of thegrinding disk 3 and gradually ground. As the electrode A is ground, theelectrode holder 7 slides down through theholder guide 6 under its own weight, and the end portion of electrode A is automatically ground in the form of a cone. When theelectrode holder 7 slides down by a certain distance, a knob of thechuck guide 7a comes to rest on an upper end of theholder guide 6, preventing theelectrode holder 7 from sliding down any further. - When the electrode A is ground for a specific time, the timer automatically switches off the
motors electrode holder 7 is pulled out of theholder guide 6 and thespacer 16 is put on theelectrode holder 7. - Then, while watching the
dial gauge 10, the movinghandle 9a of the swingplate moving mechanism 9 is turned to move the position of the axis of theholder guide 6 inwardly (i.e. in the direction of the centre of the housing 1) by aspecific distance 1. Thus, the tip of electrode A held by theelectrode holder 7 comes just above the secondgrinding part 3b of thegrinding disk 3 when theelectrode holder 7 is placed in theholder guide 6. - After the
swing plate 4 is moved to its new position, thespacer 16 is put on thechuck guide 7a of theelectrode holder 7. And theelectrode holder 7 with thespacer 16 put thereon is placed in theholder guide 6. - The thickness of the
spacer 16 is set to dimension h mentioned above. Thus, the tip of cone shaped electrode A held in theelectrode holder 7 contacts the V-shaped grindinggroove 3b' of the secondgrinding part 3b. - If the
switch 14 for the grinder motor is now turned on again, thegrinding disk 3 and theholder guide 6 turn at a specific high speed for a specific time, and theelectrode holder 7 moves down some 1.2mm under its own weight. As a result, a spherical portion of the tip of electrode A is ground to a mirror surface by the fine-grained secondgrinding part 3b. - It is noted that when the
swing plate 4 is moved, the switchover limit switch 18 is actuated to automatically switch the twomotors - FIG. 9 shows a second embodiment of the
grinding disk 3. As with thegrinding disk 3 of the first embodiment thegrinding disk 3 of the second embodiment is made in the form of a disk about 60 mm in diameter and about 8.2 mm in thickness. Thegrinding disk 3 is placed on the stepped part of the front end portion of thegrinding disk holder 2b and clamped to thegrinding disk holder 2b by tightening up the clampingscrew 13. - As is shown in FIG. 9, the
grinding disk 3 has a firstgrinding part 3a made of relative coarse grains of about #170 and a secondgrinding part 3b made of relatively fine grains of about #500. The firstgrinding part 3a and the secondgrinding part 3b are formed as step formations on the front side of the disk. - That is, the first grinding
part 3a is provided on the front side of the disk in an inner portion in the radial direction. The firstgrinding part 3a has a longitudinallyinclined surface 3a1 having an inclination with an angle α1 of approximately 10° with respect to a line perpendicular to the axis of themotor drive shaft 2a, and a transverselyinclined surface 3a2 having an inclination angle α2 of approximately 20° with respect to the axis . A joint P between the two inclined surfaces is curved in the form of an arc with a radius R of approximately 0.08 mm. - The second
grinding part 3b is provided outside the first grindingpart 3a in the radial direction and on the front side but recessed in the thickness direction, and has a longitudinallyinclined surface 3b1 having an inclination angle α1 of approximately 10° with the line perpendicular to the axis of themotor drive shaft 2a and a transverselyinclined surface 3b2 having an inclination with an angle α1 of approximately 20° with respect to the axis . An arc-shaped joint Q between the two inclined surfaces is curved with a radius R of approximately 0.08 mm. - The
distance 1 in the thickness direction of the disk (that is, the drive shaft direction of the grinder motor) is about 2.5 mm between the arc-like joint P of the first grindingpart 3a and the arc-like joint Q of the secondgrinding part 3b, and the distance h in the radial direction of the disk is set at some 3.8 mm (for electrode A with an outside diameter of 2.0 mm). - In the second embodiment, the first grinding
part 3a and the secondgrinding part 3b are identical in terms of their angles α1, α2 and radius R. Needless to say, they may be made different from each other. - Also, this second embodiment is identical to the first embodiment in terms of
distance 1 and distance h. Again, needless to say, adifferent distance 1 and a different distance h may be adopted in the second embodiment. - The procedure of grinding the electrode A using the
grinding disk 3 in the second embodiment is exactly the same as that in the first embodiment and will not be explained. - In the
grinding disk 3 of the second embodiment, the secondgrinding part 3b is open on the front side, and does not have a V-shaped groove as in the first embodiment. Therefore, the secondgrinding part 3b is hardly clogged. That substantially saves labour needed for maintenance and care of thegrinding disk 3. - FIG. 10 shows a third embodiment of the
grinding disk 3. As shown in FIG. 10, thegrinding disk 3 is some 60 mm in diameter and about 8.2 mm in thickness and is integrally formed of diamond abrasive grains (abrasive material) of a medium grain size (#350, for example) between coarse grains (#170, for example) and fine grains (#500, for example). Thegrinding disk 3 is put on the stepped part of thegrinding disk holder 2b and clamped by the grindingdisk clamping screw 13. - The
grinding disk 3 is provided with a grindingarea 3A to grind the end portion of the electrode A. Said grindingarea 3A is formed in a shape corresponding to the finished shape of the end portion of the electrode A as shown in FIG. 12. - That is, the grinding
area 3A is defined by a longitudinallyinclined surface 3a1 having an inclination angle α1 of approximately 10° with respect to the line perpendicular to the axis of themotor drive shaft 2a that grinds the end portion of the electrode A into the shape of a cone, a transverselyinclined surface 3a2 having an inclination angle α2 of approximately 20° with respect to the axis of themotor drive shaft 2a that serves to discharge grinding dust, etc., and acurved surface 3a3 or an arc-like joint between the two inclined surfaces with a radius R of approximately 0.08 mm that grinds the tip A0 of a tapered section A1 of the electrode A into a hemispherical mirror surface (for electrode A with an outside diameter D = 2.0 mm). - To grind the electrode A, the
electrode holder 7 is inserted into theholder guide 6 and, with the tip of electrode A in contact with the grindingarea 3A of the first grindingpart 3a, the switch for thegrinder motor 14 is turned on, as in the case of the first embodiment. - Then, the
grinding disk 3 is turned about the axis by thegrinder motor 2, and at the same time the electrode A is turned around the axis a by theelectrode turning motor 8. - In this way, the electrode A turns and the end portion thereof is ground on the grinding
area 3A of thegrinding disk 3 with which the electrode A is in contact. As the electrode A is ground, theelectrode holder 7 moves down in theholder guide 6 under its own weight. And the end portion of the electrode A is automatically shaped to a cone by the longitudinally inclinedsurface 3a1 of thegrinding disk 3. At the same time, the tip of the electrode A is ground and finished to a hemispherical mirror surface by thecurved surface 3a3 of thegrinding disk 3. - The reason why the electrode A is ground and finished that way is as follows. It is so arranged that the axis a of the electrode A extends along a line perpendicular to the axis of the
motor drive shaft 2a, and the grindingarea 3A of thegrinding disk 3 has a form corresponding to the finished shape of the electrode A. Furthermore, thegrinding disk 3 is turned by thegrinder motor 2, and at the same time the electrode A is turned by theelectrode turning motor 8. - When the
electrode holder 7 has moved down by a specific distance, the knob of thechuck guide 7a comes into contact with the top end of theholder guide 6 and henceelectrode holder 7 is prevented from moving down any further. - When the grinding continues for a certain time, the timer switch automatically stops the
motors electrode holder 7 is pulled out of theholder guide 6, and electrode A is taken out of theelectrode holder 7. Then electrode A is obtained with the end section in the form of a conic taper A1 and with the tip end A0 finished to a hemispherical, mirror surface as shown in FIG. 12. - To grind an electrode A with a different outside diameter or to adjust the grinding extent, the moving
handle 9a of the swingplate moving mechanism 9 is turned to move the position of the axis of theholder guide 6 along the axis of themotor drive shaft 2a by a specific distance while watching thedial gauge 10 so as to adjust the contact between the electrode A and thegrinding disk 3. - In the preceding example, the grinding
area 3A of thegrinding disk 3 is provided with a longitudinallyinclined surface 3a1, and thecurved surface 3a3 is matched to the finished shape of the electrode A as shown in FIG. 12. The present invention is not limited to that. To obtain an electrode A with an end portion having two tapered sections with different angles, that is, a two-step conical form, the grindingarea 3A may be provided with a two-stepped inclination contour, that is, two longitudinally inclined surfaces. - FIG. 11 shows a fourth embodiment of the
grinding disk 3. Thisgrinding disk 3 has two grindingareas 3A of the third embodiment symmetrically formed on both sides of a base 3c so that each of the two grindingareas 3A can be used in turn. - The procedure of grinding by this grinding
disk 3 is the same as that by thegrinding disk 3 of the third embodiment and will not be repeated. -
- a. In the present invention, it is so arranged that the axis of the electrode extends along a line perpendicular to the axis of the motor drive shaft and that the grinding part of the grinding disk is so formed to conform to the finished shape of the electrode. Furthermore, when the grinding disk is turned by the grinder motor, the electrode is turned by the electrode-turning motor at the same time. Therefore, using one grinding disk and one grinding machine for electrodes, it is possible to shape the end portion of an electrode to a final form and finish the tip to a mirror surface.
- b. In the present invention, there is provided a two-
part grinding disk 3 comprising a firstgrinding part 3a formed of coarse grains with a large grain size and a secondgrinding part 3b formed of fine grains with a fine grain size. And it is so arranged that theswing plate 4 turnably supporting theelectrode holder 7 is moved by the swingplate moving mechanism 9, and an end portion of the electrode A is ground by the first grindingpart 3a and the secondgrinding part 3b. By this arrangement, the end portion of the electrode is conically shaped by the first grindingpart 3a with relatively large abrasive grains and only the tip A0 of the electrode is polished to a mirror surface by the secondgrinding part 3b with relatively fine abrasive grains with great efficiency.It is also noted that, with electrode A held in theelectrode holder 7, the end portion of the electrode is conically shaped and the tip A0 is finished to a mirror surface using the same grinding machine for electrodes, and therefore, even when grinding is switched from conical form grinding to mirror polishing, there is no dislocation to the position of the axis of the electrode, and the tip A0 can be finished to a mirror surface efficiently and precisely. - c. In the present invention, it is so arranged that the
electrode holder 7 is moved exactly by aspecific distance 1 by the swingplate moving mechanism 9 while watching thedial gauge 10. In addition, the turning driving force is transferred to electrode A by theendless rubber belt 15, which absorbs fluctuations in thedistance 1 by shrinking or expanding. As a result, theelectrode holder 7 is turned smoothly. - d. By merely inserting the
spacer 16 in theelectrode holder 7, it is possible to adjust the height of the tip end A0 of the electrode A to a specific elevational position and to grind precisely the tip A0 alone to a mirror surface. - e. In the present invention, the grinding disk is also formed integrally of grains with the same grain size (medium grain size), with the grinding area shaped to conform to the finished contour of the electrode. That makes the manufacture easy and reduces the cost of manufacture.
- f. Also in the present invention, the axis of the electrode extends along a line perpendicular to the axis of the motor drive shaft. That substantially simplifies the construction and reduces the cost of manufacture as compared with such grinding machines in which the grinding disk itself is slanted against the electrode or the slant angle is adjusted.
- g. In the present invention, it is possible to move the electrode holder by the swing plate moving mechanism while watching the dial gauge, which permits very precise positioning of the electrode in relation to the grinding disk.
-
Claims (15)
- A grinding machine for welding electrodes, said grinding machine comprising:a box-like housing (1),a grinder motor (2) fixed in the housing (1),a disk-like grinding disk (3) provided with a grinding area (3A) and fixed on a drive shaft (2a) of said grinder motor (2),a swing plate (4) provided above the grinding disk (3) and on the housing (1) and supported movably in the direction of the axis () of the drive shaft (2a),a cylindrical holder guide (6) rotatably supported by the swing plate (4) in a vertical position with a lower portion protruded above the grinding disk (3) in the housing (1),an electrode holder (7) which is removably fitted into the holder guide (6) and which removably clamps an electrode (A) with an end portion thereof in contact with the grinding area (3A) of the grinding disk (3),an electrode turning motor (8) which is fixed in the housing (1) and which turns the holder guide (6) with the electrode holder (7) fitted thereinto, anda swing plate moving mechanism (9) which moves the swing plate (4) along the axis () of the motor drive shaft (2a) by a specific distance (1).
- The grinding machine for welding electrodes as defined in claim 1 wherein the grinding area (3A) of the grinding disk (3) is formed of a first grinding part (3a) made of coarse grains and a second grinding part (3b) made of fine grains.
- The grinding machine for welding electrodes as defined in claim 1 wherein the grinding area (3A) of the grinding disk (3) is made such that a first grinding part (3a) for shaping an end portion of the electrode (A) in the form of a cone is provided on a front side of the disk while the second grinding part (3b) provided with a V-shaped groove (3b') for polishing a tip (A0) of the conically formed end portion of the electrode (A) to a mirror surface is provided on an outer peripheral portion of the disk.
- The grinding machine for welding electrodes as defined in claim 1 wherein the grinding area (3A) of the grinding disk (3) is constituted such that a first grinding part (3a) for forming the end portion of the electrode (A) in the form of a cone and a second grinding part (3b) for polishing the tip (A0) of the conically formed end portion of the electrode to a mirror surface are both provided on a front side of the disk respectively.
- The grinding machine for welding electrodes as defined in claim 4 wherein said first grinding part (3a) is provided on an inner portion of the disk in the radial direction and on the front side thereof in the thickness direction, and the second grinding part (3b) is provided on an outer portion of the disk in the radial direction and on said front side thereof but recessed in the thickness direction.
- The grinding machine for welding electrodes as defined in claim 5 wherein the inclination angle (α1) of a longitudinally inclined surface 3a1 defining the first grinding part (3a) is the same as that of a longitudinally inclined surface (3b1) defining the second grinding part (3b); wherein the inclination angle (α2) of a transversely inclined surface (3a2) defining the second grinding part (3a) is the same as that of a transversely inclined surface (3b2) defining the second grinding part (3b); and wherein a radius (R) of an arc-like joint between the longitudinally inclined surface 3a1 and the transversely inclined surface (3a2) of the first grinding part (3a) is identical to that of an arc-like joint between a longitudinally inclined surface (3b1) and a transversely inclined surface (3b2) of the second grinding part (3b).
- The grinding machine for welding electrodes as defined in claim 1 wherein the grinding area (3A) of the grinding disk (3) is integrally formed of grains with a medium grain size.
- The grinding machine for welding electrodes as defined in claim 7 wherein the grinding area (3A) of the grinding disk (3) is provided with a longitudinally inclined surface (3a1) for shaping the end portion of the electrode (A) in the form of a cone, a transversely inclined surface (3a2) for discharging grinding dust, and a curved surface (3a3) for polishing a tip A0 of the electrode A to a mirror surface.
- The grinding machine for welding electrodes as defined in claim 1 wherein the grinding area (3A) of the grinding disk (3) is formed symmetrically on each side of the base of the grinding disk (3).
- The grinding machine for welding electrodes as defined in claim 1 wherein one end of the swing plate (4) is pivotably fixed on an upper side of the housing (1) in such a way that another end of the swing plate (4) can be moved in the direction of the axis () of the motor drive shaft (2a).
- The grinding machine for welding electrodes as defined in claim 1 wherein the electrode holder (7) comprises a cylindrical chuck guide (7a), a collet chuck (7b) to be inserted into an end side of a chuck guide (7a) and a cylindrical chuck screw (7c) inserted into the chuck guide (7a) from an upper side thereof and with a tip portion screwed into the collet chuck (7b).
- The grinding machine for welding electrodes as defined in claim 11 wherein a spacer (16) with a specific thickness (h) is put on the chuck guide (7a) of the electrode holder (7) so that a tip (A0) of the electrode (A) is positioned within a grinding groove (3b') of the second grinding part (3b).
- The grinding machine for welding electrodes as defined in claim 1 wherein the holder guide (6) with the electrode holder (7) held therein is turned by the electrode turning motor (8) via an endless rubber belt (15).
- The grinding machine for welding electrodes as defined in claim 1 wherein the swing plate moving mechanism (9) comprises a moving handle (9a) and a worm gear (9b) which is turned by the moving handle (9a) and engages with a thread (4c) provided on the swing plate (4).
- The grinding machine for welding electrodes as defined in claim 14 wherein the distance (1) by which the electrode holder (7) is moved by the swing plate moving mechanism (9) is indicated by a dial gauge (10) having a drive body (10a) which is interlocked with a gauge stopper (4b) provided on the swing plate (4).
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/JP2000/007794 WO2002040219A1 (en) | 1999-07-07 | 2000-11-06 | Welding electrode polishing machine |
Publications (1)
Publication Number | Publication Date |
---|---|
EP1250980A1 true EP1250980A1 (en) | 2002-10-23 |
Family
ID=11736658
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP00971807A Withdrawn EP1250980A1 (en) | 2000-11-06 | 2000-11-06 | Welding electrode polishing machine |
Country Status (6)
Country | Link |
---|---|
EP (1) | EP1250980A1 (en) |
KR (1) | KR100405111B1 (en) |
CN (1) | CN1188250C (en) |
CA (1) | CA2371009C (en) |
IL (1) | IL146690A (en) |
WO (1) | WO2002040219A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1637284A1 (en) * | 2004-09-17 | 2006-03-22 | Toyoda Koki Kabushiki Kaisha | Grinding wheel |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN102172899A (en) * | 2011-02-17 | 2011-09-07 | 巩亚东 | Novel superspeed point grinding wheel and grinding method thereof |
CN105108620A (en) * | 2015-06-30 | 2015-12-02 | 苏州华日金菱机械有限公司 | Welding rod welding core polishing tool |
CN109926875B (en) * | 2019-03-08 | 2024-06-04 | 河南省林晓科技开发有限公司 | Subway evacuation platform pull rod sharpening machine and processing method |
CN116728208B (en) * | 2023-08-16 | 2023-10-17 | 唐山学院 | Be used for ceramic deckle edge equipment of polishing |
Family Cites Families (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2511525Y2 (en) * | 1990-09-27 | 1996-09-25 | 彰久 村田 | Electrode rod polishing machine |
JP2577570Y2 (en) * | 1992-08-24 | 1998-07-30 | 彰久 村田 | Electrode bar polishing machine |
JP2568231Y2 (en) * | 1993-12-07 | 1998-04-08 | 彰久 村田 | Electrode bar polishing machine |
-
2000
- 2000-11-06 KR KR10-2001-7011523A patent/KR100405111B1/en not_active IP Right Cessation
- 2000-11-06 CA CA002371009A patent/CA2371009C/en not_active Expired - Fee Related
- 2000-11-06 CN CNB008157790A patent/CN1188250C/en not_active Expired - Fee Related
- 2000-11-06 EP EP00971807A patent/EP1250980A1/en not_active Withdrawn
- 2000-11-06 WO PCT/JP2000/007794 patent/WO2002040219A1/en not_active Application Discontinuation
-
2001
- 2001-11-22 IL IL146690A patent/IL146690A/en unknown
Non-Patent Citations (1)
Title |
---|
See references of WO0240219A1 * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP1637284A1 (en) * | 2004-09-17 | 2006-03-22 | Toyoda Koki Kabushiki Kaisha | Grinding wheel |
Also Published As
Publication number | Publication date |
---|---|
CN1390165A (en) | 2003-01-08 |
KR20020060576A (en) | 2002-07-18 |
IL146690A (en) | 2006-12-31 |
CA2371009A1 (en) | 2002-05-06 |
CA2371009C (en) | 2005-11-15 |
CN1188250C (en) | 2005-02-09 |
KR100405111B1 (en) | 2003-11-10 |
WO2002040219A1 (en) | 2002-05-23 |
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