Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

A METHOD OF MANUFACTURING OF REFINER DISC USING CONTINUOUS WELDING METHOD
PARASON MACHINERY (INDIA) PRIVATE LIMITED

AN INDIAN COMPANY HAVING ADDRESS AT
GOLDEN DREAMS, E-27, 4TH FLOOR CHIKALTHANA, MIDC, AURANGABAD, MAHARASHTRA INDIA, 431006

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE SUBJECT MATTER AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] This application is a Patent of Addition based on the parent application 202421068594. The present disclosure relates to improvements and modifications to the subject matter described in the parent application. This Patent of Addition should be read in conjunction with said parent application, as it further enhances or optimizes the invention described therein.

FIELD OF THE INVENTION
[002] The present invention relates to a refiner disc used in the paper pulp refining industry. Specifically, it pertains to a refiner disc manufactured using continuous welding technology to securely attach abrasive tiles to a base plate or attach ribs to the tiles, ensuring structural integrity and enhanced performance in refining operations.

BACKGROUND OF THE INVENTION
[003] In the paper pulp industry, refiner discs play a pivotal role in the mechanical treatment of pulp fibers, transforming raw fibrous materials into a refined state suitable for papermaking. These discs, typically composed of a base plate with attached abrasive tiles, operate under intense mechanical and thermal stresses during refining. Over time, conventional methods of manufacturing refiner discs have revealed inherent shortcomings, such as premature wear, detachment of abrasive tiles, and compromised welded joints. Such failures not only disrupt operations but also increase maintenance costs and reduce overall system efficiency, creating a pressing need for innovative solutions in refiner disc design and manufacturing.
[004] The present invention addresses these challenges by introducing a refiner disc design that incorporates tiles welded to the base plate or welding ribs with the tiles using continuous welding. Wherein said continuous welding produced using the seam welding method used, is uniquely suited for this application as it produces robust, overlapping welds that can withstand the high mechanical loads and thermal cycling encountered during refining. Unlike traditional spot or arc welding techniques, seam welding ensures a uniform bond along the tile’s edge, significantly reducing the risk of joint failure. This method also provides enhanced metallurgical compatibility, allowing the secure attachment of dissimilar materials often used for the tiles and base plate.

OBJECT OF THE INVENTION

[005] One of the primary objectives of using seam welding in refiner discs is to ensure the structural integrity and longevity of the discs under high-stress operating conditions. Refiner discs are subjected to significant mechanical forces and thermal stresses during operation. The continuous weld provided by seam welding helps in distributing these forces evenly across the weld seam, reducing the risk of joint failure. Additionally, the leak-proof nature of the continuous weld is critical in preventing any fluid leakage that could compromise the efficiency and safety of the refiner.
[006] Another objective of continuous welding in the context of refiner discs is its efficiency in the manufacturing process. The automated nature of continuous welding by using the seam welding method allows for high-speed production with consistent weld quality. This is particularly important in large-scale manufacturing environments where production efficiency and quality control are paramount. The precision of continuous welding by using seam welding also minimizes material wastage and the need for post-weld treatments, further enhancing the overall efficiency of the manufacturing process.
[007] Yet another objective of the use of continuous welding using seam welding in refiner discs supports their application in high-temperature and corrosive environments. The continuous weld seam offers superior resistance to thermal cycling and corrosion, ensuring that the refiner discs maintain their performance and reliability over extended periods. This makes seam welding an ideal choice for producing refiner discs that are used in demanding industrial applications, where durability and reliability are critical.

SUMMARY OF THE INVENTION
[008] A method for manufacturing a refiner disc involves several steps. First, a base plate is provided. Then, a plurality of ribs (501) and a flow restrictor (502) are configured with a tile (202). The tile (202) features a plurality of grooves (203) across its surface, parallel to each other and designed to accommodate the ribs (501) and the flow restrictor (502). These grooves (203) include multiple exits articulated in configurations such as step-up, step-down, curved, inclined, inline, up-down, spiral, and combinations thereof, created using a single setup of machining tools like drilling machines, CNC machines, laser drilling, wire cutting, or combinations thereof. The tile (202) is then further configured with the base plate (101) to form the refiner disc (100).
[009] Continuous welding using seam welding is employed to securely attach the ribs (501) and the flow restrictor (502) to the tile (202) and the base plate (101). The welding torch (201) is guided by advanced path-following technology using laser and image recognition systems to follow the predefined paths of the grooves (203), applying continuous or overlapping welds to ensure a strong bond between the ribs (501), flow restrictor (502), and the tile (202). An image recognition system, including an Image Processing Unit (401), captures and analyses images of the welding tracks and grooves (203) on the components, detecting deviations from the intended welding path and converting these deviations into deviation signals.
[0010] The deviation signals are sent to a PID Controller (402), which receives these signals and uses proportional, integral, and derivative units to compute corrective actions, generating control signals. These control signals are transmitted from the PID Controller (402) to a Torch Controller (403), which adjusts the position and parameters of the welding torch (201) to ensure it follows the welding path precisely. The welding operation is performed by the welding apparatus (404), applying continuous or overlapping welds along the grooves or slots (203) or tracks (102), with adjustments made by the Torch Controller (403) to ensure high precision and accuracy.
[0011] The overall operation of the welding system is managed by a Central Processing Unit (CPU) (405), integrating signals from the Image Processing Unit (401) and the PID Controller (402) to coordinate and control the entire welding process, ensuring seamless communication between all components and maintaining optimal performance and efficiency.
[0012] In an embodiment, the present invention discloses using a clamping fixture or jig (103) to assemble or weld components of the refiner disc, wherein the base plate (101) is held securely in place by the clamps (103) during the welding process to ensure precise alignment and uniformity of the tiles (202).
[0013] In yet another embodiment, the present invention discloses positioning the welding torch (201) above the base plate (101) to perform the seam welding process, following a curved welding path along the grooves or slots (203) on the tiles (202), and applying continuous or overlapping welds to securely attach the components to the base plate (101).
[0014] In still another embodiment, the present invention discloses utilizing a laser guiding method or an image recognition system within the continuous welding apparatus (201) to automatically track the welding process along the tracks (102) and grooves (203), ensuring the welding torch (201) follows the desired trajectory with high precision.
[0015] In yet another embodiment, the present invention discloses maintaining the desired welding path and parameters by using a PID Controller (402) that receives deviation signals from the Image Processing Unit (401) and generates control signals accordingly.
[0016] In an embodiment, the present invention discloses adjusting the position and parameters of the welding torch (201) with a Torch Controller (403) based on the control signals generated by the PID Controller (402), ensuring high precision and accuracy in the welding process.
[0017] In an embodiment, the present invention discloses performing the welding operation by applying continuous or overlapping welds with the welding apparatus (404) along the grooves or slots (203) or tracks (102), securely attaching the components to the base plate (101).
[0018] In still another embodiment, the present invention discloses managing the overall operation of the welding system with a Central Processing Unit (CPU) (405), integrating signals from both the laser guiding system or Image Processing Unit (401) and the PID Controller (402) to coordinate and control the entire welding process, ensuring seamless communication between all components.
[0019] In an embodiment, the present invention discloses using a welding torch (201) that comprises a laser, TIG, or MIG torch, capable of moving along the edges of the grooves or joints of the tracks (102) or grooves (203) to create a continuous weld.
[0020] In an embodiment, the present invention discloses applying constant pressure with clamps (103) to ensure the molten material fuses properly during the welding process, forming a strong weld when cooled and maintaining the structural integrity of the refiner disc (100).
[0021] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF DRAWINGS
[0022] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of systems or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:

[0023] FIG. 1: illustrates a Clamping Fixture for a base plate of the refiner disc assembly.

[0024] FIG. 2: illustrates a manufacturing setup for a refiner disc, with a particular focus on the continuous welding process.

[0025] FIG. 3: illustrates a close-up view of the continuous welding process for a refiner disc assembly

[0026] FIG. 4: illustrates the block diagram of the components of the continuous welding apparatus or torch.

[0027] FIG. 5: illustrates the embodiment of the continuous welding used for welding the ribs accommodating within the grooves.

[0028] FIG. 6: illustrates the embodiment of the continuous welding used for welding the ribs and dams accommodating within the grooves.

[0029] FIG. 7: illustrates the block diagram of the components of the continuous welding apparatus or torch.

[0030] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

LIST OF REFERENCE NUMERALS

References Numerals
Refiner disc 100
Base plate
101
Tracks
102
Clamping fixture or jig 103
Welding apparatus or torch
201
Circular feature or a mounting hub or a ring or tiles
202
Grooves or slots 203
Laser Guided system or Image Processing Unit 401
PID Controller 402
Torch Controller 403
Welding Apparatus 404
Central Processing Unit (CPU) 405
Ribs
501
Flow restrictor
502
Laser scanner 601
Control unit 602
PID Controller 603
Torch Controller 604
Welding apparatus 605
Central Processing Unit (CPU) 606

DETAILED DESCRIPTION OF INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS
[0031] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

[0032] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or device.

[0033] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.

[0034] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

[0035] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.

[0036] The present invention introducing a refiner disc design that incorporates abrasive tiles welded to the base plate using continuous welding. Said continuous welding, a seam welding method, is uniquely suited for this application as it produces robust, overlapping welds that can withstand the high mechanical loads and thermal cycling encountered during refining.

[0037] Further, in present invention another feature lies in the formation of grooves on the tiles by continuous welding. The grooves are strategically designed in radial or spiral patterns, ensuring uniform pulp flow and effective fiber treatment. Additionally, the grooves help distribute stresses and accommodating ribs more evenly across the disc, minimizing the likelihood of structural failures.

[0038] By combining the precision of continuous welding with the functional benefits of a grooved tiles, welding the ribs on the tiles, the invention delivers a refiner disc that offers superior durability, operational efficiency, and reliability. The robust construction ensures that the abrasive tiles remain securely attached throughout the lifecycle of the disc, even under demanding operating conditions. This not only extends the lifespan of the refiner disc but also reduces the frequency of maintenance, resulting in significant cost savings and improved productivity for pulp refining operations. Through this innovation, the present invention provides a transformative solution to longstanding challenges in the paper pulp industry.

[0039] Figure 1 illustrates a clamping fixture or jig for assembling or welding components of a refiner disc. The primary component visible in Figure 1 is a circular plate, which is a base plate (101) of the refiner disc. This base plate (101) is where abrasive tiles are usually mounted for refining applications. The tracks (102) along the plate (101) likely correspond to areas designed for mounting abrasive tiles. These tracks (102) may serve as guides for positioning the tiles or as structural features to enhance bonding and operational efficiency during the refining process. Clamps (103) mounted radially around the base plate suggest that this setup is used during the manufacturing or assembly process. These clamps (103) are likely used to: hold the abrasive base plate (101) or components in place while they are being welded or bonded. These clamps (103) ensure precise alignment of the tiles to maintain uniformity and operational balance. The setup shown in figure 1 may specifically be designed for continuous welding using seam welding, as the clamps (103) secure the base plate (101) tightly against each other. Seam welding typically requires the components to be in close contact to ensure strong, continuous welds. Figure 1 shows the initial part of the fabrication process for a refiner disc. The image depicts a fixture that ensures accurate placement and attachment of the base plate (101), potentially using seam welding as the joining method. This setup ensures precision and structural integrity in the finished refiner disc.
[0040] In an embodiment as shown in figure 2, depict a manufacturing setup for a refiner disc, with a particular focus on the seam welding process. At the core of the setup is a large circular base plate (101), which features tracks (102) that are likely designed to position and attach other base plates (101) or tiles by welding. These tracks (102) guide the placement of the tiles and the fixing of base plate (101) with each other. Additionally, the tracks (102) enhance the strength of the welded joints by increasing the surface area available for bonding.
[0041] The central clamping area shown by clamps (103) includes a circular feature (202), possibly a mounting hub or a ring, that is being welded or attached. Multiple clamps (103) are strategically placed radially around the base plate (101) to hold the circular components firmly in position. These clamping mechanisms (103) ensure stability and precision during the welding process, preventing any movement that could compromise the quality of the weld. The meticulous arrangement of clamps highlights the importance of maintaining precise alignment and stability in such high-precision manufacturing.
[0042] Further, Figure 2 illustrates the welding apparatus or torch (201) positioned above the plate (101), indicating the seam welding process. In this process, a continuous or overlapping weld is applied to securely join components, such as the central ring or tiles (202), to the base plate. The welding is likely performed along a circular path, following the grooves on the central ring or tiles (202). This ensures a strong, durable bond between the components, which is essential for the refiner disc's performance. Laser guided system or Image recognition technology within the continuous welding apparatus (201) automatically tracks the continuous welding process along the tracks (102) to weld the base plate (101) together and automatically tracks the grooves (203) of the central ring or tiles (202) so that the tiles (202) can be welded on the desired location of the base plate (101). Additionally, a PID (Proportional-Integral-Derivative) controller is employed to maintain the desired welding path and parameters. This advanced setup ensures high precision and consistency, effectively capturing the complexity and precision required in the continuous welding process and emphasizing the importance of each element in achieving a high-quality final product.
[0043] In an another embodiment, figure 3 illustrates a close-up view of the continuous welding process for a refiner disc assembly, highlighting several key features that contribute to its functionality. At the heart of the setup is the welding torch (201), the central component that performs the continuous welding operation. The torch (201) is seen following a curved welding path along the grooves or slots (203) on the tiles (202), ensuring a continuous weld that securely attaches components like tiles or reinforcing structures on the base plate (101). These grooves or slots (203), depicted in green, guide the welding process, ensuring precise alignment and placement of the welds. The welding path tracking by the torch (201) is a crucial aspect of this process. Figure 3 symbolize the welding path being tracked by the system, which suggests the use of image recognition or path-following technology using laser guided system. This technology ensures that the welding torch (201) follows the desired trajectory with high precision. The continuous welding precision is further emphasized by the positioning of the welding torch, which applies a continuous weld along the groove (203) edges. This meticulous welding process creates a strong bond that withstands operational stresses such as thermal cycling and mechanical forces, which are common during the refining process. The background of Figure 3 shows support clamps, indicating that the components are securely held in place during welding, thereby ensuring accurate alignment and minimizing the risk of distortion caused by welding heat. Further, the torch (201), which may comprise a laser, TIG, or MIG moves along the edges of the grooves or joints of the tracks or grooves to create a continuous weld. The welding torch (201) is programmed or guided to follow the exact welding path using automation, such as image recognition or laser-guided system. In torch (201) a high electrical current is passed through an electrode. The electrical resistance at the joint generates localized heat. This heat melts the edges of the components, creating a molten weld pool. The clamps apply (103) constant pressure to ensure the molten material fuses properly, forming a strong weld when cooled. The welding torch (201) moves along the seam at a controlled speed.
[0044] The overall functionality of the system demonstrates advanced automated continuous welding with sophisticated path tracking. The grooves on the base plate provide both mechanical support and precise alignment for the welding process, while a combination of image recognition technology and a PID (Proportional-Integral-Derivative) controller likely controls the movement of the torch (201). This integration ensures precise welding along curved and complex paths, resulting in strong and uniform welds that significantly improve the durability and performance of the refiner disc. The design underscores the importance of automation and precision in manufacturing high-performance industrial components, such as refiner discs, emphasizing the role of advanced technologies in achieving superior quality and consistency.
[0045] Figure 4 illustrates the block diagram of the components used and their operation thereof in the seam welding. Initially, in the seam welding apparatus or torch (201), an image Processing Unit (401) captures and analyses images of the welding tracks and grooves of the components such as base plate and tiles. This unit (401) is responsible for detecting any deviations from the intended welding path. The detected deviations are then converted into deviation signals, which are sent to the PID Controller (402). The PID controller (402) receives these deviation signals and utilizes its proportional, integral, and derivative units to compute the necessary corrective actions. Based on these calculations, the PID controller generates control signals. These control signals are subsequently sent to the Torch Controller (403), which adjusts the position and parameters of the welding torch to ensure it follows the precise welding path as determined by the image processing unit and corrected by the PID controller (402). The welding torch, part of the Welding Apparatus (404), performs the actual welding operation by applying continuous or overlapping welds along the grooves or slots (203) or tracks (102) to securely attach components. The adjustments made by the torch controller ensure high precision and accuracy in the welding process.
[0046] Finally, the overall operation of the system is managed by the Central Processing Unit (CPU) (405). The CPU (405) integrates signals from both the image-processing unit or the laser scanner and the PID controller to coordinate and control the entire welding process. It ensures seamless communication between all components, maintaining optimal performance and efficiency. This structured integration of components highlights the importance of each element in achieving precise and efficient welding, demonstrating the complexity and precision required in such advanced manufacturing processes.
[0047] In another embodiment, Figure 5 (a) and 5 (b) illustrate the different types of grooves (202) formed on the surface of tiles (203) configured by the continuous welding method. This figure illustrates that continuous welding may track grooves (202) on the tiles if the desired path of joining the grooves (202) is known to the welding torch (201). The welding torch (201), equipped with advanced path-following technology and possibly guided by image recognition systems or a laser tracking system that can accurately follow the predefined trajectory to configure said grooves (202). This process involves the torch (201) moving along the desired path, applying a controlled amount of heat and pressure to form the grooves directly on the tile surfaces. The precision of this method ensures that the grooves (202) are formed consistently and uniformly, which is crucial for the performance and functionality of the tiles.
[0048] This capability to form grooves (202) using continuous welding opens up new possibilities in manufacturing and configuration, allowing for intricate patterns and structural enhancements to be directly incorporated into the tiles. The integration of advanced control systems, such as image recognition or laser tracking (401) and PID controllers (402), ensures that the welding torch (201) can execute complex and precise movements, thereby expanding the applications of continuous welding beyond traditional joining processes. This innovative approach underscores the importance of automation and precision in modern manufacturing techniques.
[0049] In an another embodiment, Figure 6 illustrate the continuous welding used for welding ribs (501) and flow restrictor (502) within the grooves (203). In an embodiment, the present disclosure provides a refiner disc (100) comprising a base plate (101), a plurality of ribs (501), and a tile (202). The plurality of ribs (501) is configured with the tile (202), and the tile (202) is further configured with the base plate (101) to collectively form the refiner disc (100). The tile (202) features a plurality of grooves (203) formed across its surface, which are parallel to each other and designed to accommodate the plurality of ribs (501). These grooves (203) include multiple exits and are articulated in various configurations such as step-up, step-down, curved, inclined, inline, up-down, spiral, and combinations thereof. The grooves (203) are created using a single setup of machining tools, including but not limited to options such as a drilling machine, CNC machine, laser drilling, wire cutting, etc., or combinations thereof.
Additionally, continuous welding is employed to securely attach the ribs (501) and flow restrictor (502) to the tile (202) and base plate (101). The welding torch (201), guided by advanced path-following technology and possibly image recognition systems or the laser-guided system, follows the predefined paths of the grooves (203). It applies continuous or overlapping welds along these paths, ensuring a strong bond between the ribs (501), the flow restrictor (502), and the tile (202). The precision of the continuous welding process is crucial for maintaining the alignment and structural integrity of the refiner disc (100), especially in configurations with complex groove patterns. This integration of advanced machining and welding techniques ensures the high performance and durability of the refiner disc (100) for demanding industrial applications.
[0050] In an embodiment, the present invention discloses an advanced solution designed to enhance the accuracy and efficiency of automated welding in the manufacturing of a refiner disc (100). This embodiment includes a welding torch (201) that employs advanced path-following technology and a laser scanner that continuously emits a laser beam to detect the seam or joint between work pieces. The laser scanner captures real-time data on the seam’s position and geometry, ensuring precise tracking. This information is processed by a control unit, which interprets deviations and adjusts the welding torch’s position dynamically. This information is processed by a control unit, which utilizes proportional, integral, and derivative (PID) control algorithms to interpret deviations and dynamically adjust the welding torch’s position. The torch (201), mounted on a robotic arm or movable platform, aligns with the seam based on these real-time adjustments, ensuring uniform and defect-free welding while applying continuous or overlapping welds along the grooves or slots (203) to securely attach the plurality of ribs (501) and the flow restrictor (502) to the tile (202), as well as the tile (202) to the base plate (101).
[0051] The system operates through a continuous feedback loop where the laser scanner (601) monitors the seam, transmitting data to the control unit (602), which then analyzes and corrects misalignments using PID control (603) to compute corrective actions. If there are variations in the workpiece geometry, the system immediately adjusts the torch’s path (604), accommodating complex welding trajectories across multiple axes. The welding apparatus (605) performs the actual welding operation, ensuring high precision and accuracy through adjustments made by the torch controller (604). A software interface and Central Processing Unit (CPU) (606) allow operators to configure parameters, monitor system performance, and receive maintenance alerts, enhancing usability and ensuring a strong bond between the components of the refiner disc (100).
[0052] Although embodiments for the present subject matter have been described in language specific to structural features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/component of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the scope of the present subject matter.

Dated this 15th day of April 2025

Shailendra Om Khojare,
IN/PA-4041
Applicants Patent Agent

, Claims:

CLAIMS
We claim:
1. A method for manufacturing a refiner disc (100) using continuous welding comprising the steps of:
providing a base plate (101);
configuring a plurality of ribs (501) and a flow restrictor (502) with a tile (202), wherein the tile (202) features a plurality of grooves (203) formed across its surface, which are designed to accommodate the plurality of ribs (501) and the flow restrictor (502), the grooves (203),
configuring the tile (202) with the base plate (101) to collectively form the refiner disc (100);
employing continuous welding using the seam welding method to securely attach the plurality of ribs (501) and the flow restrictor (502) to the tile (202), and employing continuous welding to securely attach the tile (202) to the base plate (101),
wherein the welding torch (201) is guided by advanced path-following technology of laser scanning or image recognition systems to follow the predefined paths of the grooves (203), applying continuous or overlapping welds along these paths to ensure a strong bond between the ribs (501), flow restrictor (502), and the tile (202).
2. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein said image recognition system within the welding torch (201) includes an image processing unit (401) to capture and analyze images of the welding tracks and grooves (203) on the components, detecting deviations from the intended welding path, and converting these deviations into deviation signals, and sending the deviation signals to a Controller (402) configured to receive the signals and utilizes proportional, integral, and derivative units to compute corrective actions, generating control signals for transmitting the control signals from the controller (402) to a torch controller (403), which adjusts the position and parameters of the welding torch (201) to ensure precise following of the welding path in order to performing the actual welding operation by a welding apparatus (404) by applying continuous or overlapping welds along the grooves or slots (203) or tracks (102), with adjustments made by the torch controller (403) to ensure high precision and accuracy and managing the overall operation of the welding with a central processing unit (CPU) (405), integrating signals from both the image-processing unit (401) and the controller (402) to coordinate and control the entire welding process.
3. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein a clamping fixture or jig (103) used to assemble or weld components of the refiner disc (100), and the base plate (101) is held securely in place by the clamps (103) during the welding process to ensure precise alignment and uniformity of the tiles (202).
4. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein the positioning of the welding torch (201) is above the base plate (101) to perform the continuous welding, following a welding path along the grooves or slots (203) on the tiles (202), and applying continuous or overlapping welds to securely attach the components to the base plate (101).
5. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein automatic tracking of the image recognition system (401) within the continuous welding apparatus (201) the welding process along the tracks (102) and grooves (203) performed to ensuring the welding torch (201) follows the desired trajectory with high precision.
6. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein the PID Controller (402) determines the desired welding path and parameters by receiving deviation signals from the Image Processing Unit (401) and generating control signals accordingly.
7. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein adjusting the position and parameters of the welding torch (201) by the torch controller (403) based on the control signals generated by the PID Controller (402), ensuring high precision and accuracy in the welding process.
8. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein the welding apparatus (404) performing the welding operation by applying continuous or overlapping welds along the grooves or slots (203) or tracks (102), securely attaching the components to the base plate (101).
9. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein the welding torch (201) comprises a laser, TIG, or MIG torch, capable of moving along the edges of the grooves or joints of the tracks (102) or grooves (203) to create a continuous weld.
10. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein the clamps (103) apply constant pressure to ensure the molten material fuses properly during the welding process, forming a strong weld when cooled and maintaining the structural integrity of the refiner disc (100).
11. The method for manufacturing a refiner disc (100) as claimed in claim 1, wherein the Central Processing Unit (CPU) (405) manages the operation of the welding system to coordinate and control the entire welding process.
12. A refiner disc (100) comprising:
a base plate (101),
a plurality of ribs (501),
a flow restrictor (502),
a tile (202) featuring a plurality of grooves (203) formed across its surface, which are designed to accommodate the plurality of ribs (501) and the flow restrictor (502),
wherein the plurality of ribs (501) and the flow restrictor (502) are configured with the tile (202), and the tile (202) is configured with the base plate (101) to collectively form the refiner disc (100);
wherein continuous welding using seam welding method is employed by a welding torch (201) to securely attach the plurality of ribs (501) and the flow restrictor (502) to the tile (202) and the base plate (101), the welding torch (201) guided by advanced path-following technology using laser guiding and image recognition systems, follows the predefined paths of the grooves (203), applying continuous or overlapping welds along these paths, ensuring a strong bond between the ribs (501), flow restrictor (502), and the tile (202).
13. A refiner disc (100) as claimed in claim 12; wherein said image recognition system comprises an image processing unit (401) within the welding torch that captures and analyses images of the welding tracks and grooves (203) detecting deviations from the intended welding path and converting these deviations into deviation signals sent to a PID Controller (402), and the PID Controller (402) receives the deviation signals and utilizes proportional, integral, and derivative units to compute corrective actions, generating control signals sent to a torch controller (403), which adjusts the position and parameters of the welding torch (201) to ensure precise following of the welding path in order to allow the welding apparatus (404) to performs the actual welding operation by applying continuous or overlapping welds along the grooves or slots (203) or tracks (102), with adjustments made by a torch controller (403) and the overall operation of the welding apparatus (404) is managed by a Central Processing Unit (CPU) (405), integrating signals from both the Image Processing Unit (401) and the PID controller (402) to coordinate and control the entire welding process.

Dated this 15th day of April 2025

Shailendra Om Khojare,
IN/PA-4041
Applicants Patent Agent