Belt-configured saw for cutting slots into stones

Abstract: A stone cutting belt (20) includes a flexible and continuous main body (45) with length and lateral width, having a top surface and a bottom surface. The belt (20) includes a plurality of cutter segments (19), each comprising a preferably metallic drive block (24) and a metallic carrier block (35) mounted on the top surface (24a) of the drive block (24). The carrier block (24) includes a tooth slot (42) in which a cutting tooth (40) is mounted, such as by silver soldering. The cutting teeth are arranged in a repeated pattern including two groups of teeth.

Description: This invention relates to stone cutting devices in general, and in particular to such a device having a flexible and continuous stone cutting belt. More particularly, the invention relates to a stone cutting device comprising: a main frame; a jib movably mounted to said frame; a pair of spaced apart sheaves rotatably mounted to said jib; means on said main frame for rotating said sheaves; and a belt extending around said sheaves, said belt comprising a flexible and continuous belt-shaped main body with length and lateral width, said main body having a substantially flat top surface and a bottom surface, said bottom surface being adapted to engage said sheaves; and a plurality of stone cutting elements mounted in said main body and arranged in such a manner that said plurality of elements are spaced along the length of the main body. Various means have been developed over the years for cutting and removing hard natural stone from quarries. In US-A-3 884 212, there is disclosed an improved wire saw that is adaptable for cutting stone which is still in the ground. This wire saw includes abrasive cutting elements sleeved over an endless flexible wire, and a pressure molded-in-place resilient material surrounding the cable and providing a substantially uniform diameter for the endless saw. In another method for removing stone from the ground, it is known to drill holes in stone and then wedge large pieces of stone out with mechanical means employing hydraulics and pneumatics. This method is difficult, time consuming, and does not result in a smooth, cut surface on the stone. A device known to be used in Europe includes a jib pivotally mounted to a vehicle having aligned sprockets and a guidebar to drive a continuous chain on which diamond cutting bits are attached for cutting stone. The jib travels through the stone as it is cut away by the chainsaw. Several problems are associated with using this chain-type saw. The chain is heavy, expensive, and must be run at slow speeds because of its mechanical construction. The chain also causes vibration, or chatter, during operation and wears out easily. Should the chain break during operation, it may perilously fly off the jib. In US-A-4 603 678 there is disclosed an improved belt-configured saw for cutting a slot in stone, comprising a mainframe, a jib movably mounted to the mainframe, and a continuous flexible belt extending around and in driven engagement with sheaves on the jib. The belt includes a plurality of spaced apart abrasive cutting strips extending across the top and sides of the belt. This belt-configured saw employs a grinding action rather than a cutting action to remove the stone. Since this belt-configured device operates by a grinding action, greater energy is required to drive the belt than would ordinarily be required for a device operating by a cutting action. In addition, the grinding action of this type of belt-configured saw requires higher belt tension so that the abrasive cutting strips can be fully operative. Moreover, the abrasive cutting strips, produced from a powdered metal mix, such as bronze having diamonds positioned uniformly throughout, are expensive and difficult to produce. European patent application EP-A-0 028 418 discloses a stone cutting chain saw provided with a plurality of cutting tools supported by the chain, said cutting tools being arranged at different angular locations, so as to form a semi-circular pattern. Such a chain saw comprises a number of links and not a continuous main body, such as a belt, and each cutting tool is mounted in a holding head which is connected to, or integral with, the part of each tool-supporting link which forms the chain, said holding head being entirely located above said part of the link. A chain saw of that type presents significant noise and vibration problems, such as through the rattling of the link of the chain. The vibration tends to reduce the life of such chain saw. US-A-4 679 541 discloses a stone cutting device of a kind comprising the general features indicated in the introductory part of the present description (corresponding to the preamble part of claim 1 thereof), with cutting elements constituted by abrasive strips which completely span the width of the belt. Said device, which comprises a cutting belt instead of a cutting chain, overcomes, or at least greatly reduces the above mentioned noise and vibration problem, but it does not have an optimum cutting efficiency. In accordance with the present invention, one object is to provide an improved stone cutting device employing a stone cutting belt, that is adapted for cutting stone which is in the ground. Another object is to provide a device for high speed cutting of a slot in stone which is in the ground. Another object of the present invention is to provide a device for removing stone by a cutting action rather than by a grinding action, thereby reducing the power required to drive the cutting device. Yet another object is to provide a device that minimizes the vibration or chatter associated with the cutting operation. To that effect, the stone cutting device according to the invention is characterized in that each of said elements has a width substantially less than the lateral width of said main body, and a portion of each of said cutting elements projects above said top surface of the main body while the remainder portion of each cutting element is held in the main body, wherein said cutting elements are staggered across the width of said main body in a pattern to form a continuous cutting width at least equal to the width of said main body. The stone cutting elements may include a poly-cristalline diamond tooth in a tungsten carbide substrate. FIG. 1 is a side view of the jib comprising a portion of a stone cutting device in the preferred embodiment of the present invention. FIG. 2 is a fragmentary enlarged cross-sectional view of a portion of the jib shown in FIG. 1, taken along line 2-2 in FIG. 1 and viewed in the direction of the arrows. FIG. 3 is an enlarged orthographic view of the belt portion of the jib shown in FIG. 1, with the resilient body portion of the belt shown in phantom for clarity. FIG. 4 is a reduced fragmentary top view of the belt engaged on the jib shown in FIG. 1, taken along line 4-4 in FIG. 1 and viewed in the direction of the arrows. FIG. 4a is an enlarged view of a portion of the belt illustrated in FIG. 4 showing the arrangement of cutting teeth along the belt. FIG. 5 is a side cross-sectional view of a drive block comprising a portion of the belt in one alternate embodiment of the present invention. FIG. 6 is an enlarged side cross-sectional view of a drive block in a belt of another embodiment of the present invention. For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. The preferred embodiment of the present invention is a device for cutting a slot in stone located in the ground, including a vehicle atop rails as is known in the art and as is described in my US-A-4 679 541. The vehicle includes a jib 10, shown in FIG. 1, pivotally mounted to the mainframe of the vehicle. The jib 10 includes a pair of sheaves 11 and 12 mounted to the opposite ends of the jib. A jib frame 13 supports the sheaves 11 and 12 at opposite ends of the frame. Typically, sheave 11 will be situated above ground and will be driven by suitable means mounted in the vehicle. The jib frame 13 includes groove members 14 and 15 mounted to the top and bottom edges of the frame in a conventional manner. Belt 20 extends in a continuous fashion around sheaves 11 and 12 and immediately adjacent and in contact with groove members 14 and 15. The details of the construction of the belt 20 are illustrated with reference to the cross-sectional view in FIG. 2. The belt 20 includes a plurality of cutter segments 19, each comprising a drive block 24 with a carrier block 35 mounted on the top surface of the drive block by suitable means. In the preferred embodiment, both the drive block 24 and the carrier block 35 are composed of a metal, such as a mild steel suitable for investment casting. The carrier block 35 is brazed onto the drive block 24. The carrier block includes a front face 35a with a tooth slot 42 formed therein in which a cutting tooth 40 is mounted. The tooth 40 is situated within the slot 42 and contacts the top surface 24a of the drive block 24. The tooth is suitably affixed into the slot 42, such as by silver soldering. The back wall 43 of the tooth slot 42 is slanted rearward at a rake angle, as shown in FIG. 3, relative to the direction of travel of the belt 20, designated by the heavy arrows in FIGS. 3 and 4. In the preferred embodiment, a rake angle of 7°, relative to the vertical, provides suitable tooth clearance above the top surface 36. At this orientation, the cutting tooth 40 is not prone to "grab" the stone during the cutting operation, which results in a better cutting action with less vibration than in prior art devices. As illustrated in FIGS. 4 and 4a, cutting teeth 40 are mounted at the lateral edges of the belt 20, and consequently at the lateral edges of the carrier block 35. Since the drive block 24 in the preferred embodiment extends only partially across the lateral width of the carrier block, as shown in FIGS. 2 and 3, the teeth 40 situated at the lateral edges of the carrier block 35 do not contact the top surface 24a of the drive block. Although the silver solder is sufficient to hold the tooth within the slot 42 once the belt 20 is assembled, a special assembly procedure is used to mount the tooth. A graphite locator block (not shown in the figures) is placed under the overhanging portion of the carrier block 35 adjacent the drive block 24. The tooth 40 can then be placed in the slot 42 and contact the top surface of the locator block to position the tooth properly during the soldering operation. Once the tooth is firmly affixed within the slot, the locator block is removed. In the preferred embodiment, the cutting tooth 40 comprises poly-crystalline diamond mounted in a tungsten carbide substrate, such as is manufactured by the General Electric Corporation as Model #1575 and distributed under the tradename "Compax" by Van Itallie, of Saddlebrook, New Jersey. In essence, the tooth 40 comprises a large number of small diamonds held together by a substrate or filler. The diamond cutting tooth projects beyond top surface 36 of carrier block 35, and beyond top surface 21 of belt 20, which is flush with top surface 36 of the carrier block as will be described herein. In practice, it has been found that the optimum height or clearance of the cutting tooth above the top surfaces 36 and 21 is about 0,762 mm (0.030 inches) At this dimension, optimum cutting performance is achieved with a minimum of vibration or tooth chatter. Moreover, there is little risk of chipping or shearing the top of the cutting tooth 40 at this selected height dimension. The drive block 24 includes a number of bores 27 extending through the drive block along the length of the belt 20. Wire cables 30 pass through each of the bores 27 individually, each of the cables being continuous through the length of the belt 20 to increase the strength of the belt. As shown in FIG. 3, the drive block 24, carrier block 35, and cables 30 are embedded in a resilient body 45. The resilient body 45 extends throughout the entire length of the belt 20 and is used to position the plurality of cutter segments 19 along the length of the belt. The belt 20 is formed by placing the cutter segment 19 in an injection mold, with the mold being at approximately 150°F. Polyurethane is then injected into the mold to encapsulate the cutter segments 19 and the continuous cables 30. During the injection molding process, the polyurethane also infiltrates the bores 27 in drive block 24 to surround the cables 30 and securely anchor the drive block 24 to the cables 30. The cutter segment 19 is positioned in the injection mold so that the top surface 36 of the carrier block 35 is positioned flush with the top surface 21 of the belt 20 or resilient body 45. Likewise, the opposite sides of the carrier block and the resilient body are flush. In the injection molding process, the resilient body 45 is formed with a drive projection 22 (FIGS. 2 and 3) extending from the bottom surface of the belt 20 along the length of the belt. The drive projection 22 extends into grooves 16 and 17 of groove members 14 and 15 of the jib frame 13. The drive projections 22 engage the complementary-shaped outer circumferences of sheaves 11 and 12 so that the belt 20 can be driven by the rotation of the sheave 11. A top view of the belt 20 is shown in FIG. 4. The belt 20 includes a plurality of cutter segments 19 spaced along the length of the belt, with portions of the resilient body 45 separating each cutter segment. In a cutaway portion of the belt shown in FIG. 4, the positioning of the drive block 24, carrier block 35, cutting tooth 40, and cables 30 are shown. Each cutting tooth 40 is positioned at the upstream face of the carrier block 35, as determined by the direction of travel of the belt 20 indicated by the heavy arrow in FIG. 4. The width of each of the cutting teeth 40 is substantially smaller than the width of the belt 20, so that in the preferred embodiment a first group 50 of thirteen cutting teeth staggered in the pattern shown in FIG. 4 are required to span the entire width of the belt. As shown in FIG. 4, the carrier blocks 35 extend laterally across the entire width of the belt 20. Alternatively, the carrier blocks may extend only partially across the belt width, with the resilient body 45 filling the remaining space. In the preferred embodiment, the cutting teeth 40 on consecutive cutter segments 19 are arranged to converge alternately from each of the opposite sides of the belt 20. The teeth 40 are arranged such that the lateral distance between pairs of alternate cutting teeth is less than the width of one tooth. Thus, in the preferred embodiment, the distance between alternate cutting teeth is essentially zero. The opposing lateral edges of alternate cutting teeth are coplanar with a plane aligned along the length of the belt, as represented by the dashed lines in FIG. 4. For example, referring to the teeth labeled A and B in FIG. 4 and shown in the enlarged view in FIG. 4a, the right edge R of tooth A is in line with the left edge L of tooth B. Cutting teeth in consecutive cutter segments continue to converge in this fashion toward the center of the belt 20 until a continuous cutting width has been formed that is at least equal to the lateral width of the belt. The first group of thirteen cutting teeth 40, arranged as just described with opposite edges aligned, can generate streaks in the stone along the cutting path coinciding with the dashed lines in FIG. 4 representing the aligned edges of alternate cutting teeth. In order to eliminate these streaks, a second group 52 of cutting teeth is provided. The second group 52, beginning with the cutting tooth labeled C in FIG. 4, follows a similar alternately converging pattern as the first group 50, with the exception that the teeth are staggered to cut along the streak lines generated by the first group of cutting teeth. That is, the planes representing the aligned lateral edges of teeth in the first group 50 intersect at least one of the teeth in the second group 52. Thus, the streak line formed by cutting teeth labeled A and B is eliminated by the cutting tooth labeled D in the second group 52 of stone cutting teeth. In the preferred embodiment, fifteen teeth are used in the second group 52. The pattern formed by the two groups of cutting teeth 40, the upstream group having thirteen teeth and the downstream group having fifteen teeth, is repeated throughout the entire length of the belt 20. This repeated pattern of cutting teeth 40 ensures that a complete cut is made across the width of the belt 20 without the presence of streaks along the length of the belt. It is apparent, however, that other patterns of cutting teeth are contemplated by the present invention, provided that a continuous cutting path or swath is defined. In order to further reduce the possibility of streaks along the belt, the leading edges 41 of each of the cutting teeth 40 are rounded. The rounded leading edges 41, along with the staggered arrangement of cutting teeth in the above-described pattern, also helps eliminate vibration or chatter of the belt during a stone cutting operation. The drive block in each cutter segment 19 contains a bore therethrough as previously described. In an alternate embodiment of the present invention, a drive block 60, as shown in FIG. 5, includes a bore 61 having opposite arcuate interior walls 62 and 63. The features of the belt in this alternate embodiment are identical in all other respects to the previous embodiment. The arcuate walls 62 and 63 form a necked-down portion of bore 61 that is sufficiently large to allow a cable 59 to extend through the bore 61 without contacting either of the arcuate walls. Once the polyethylene has been introduced into the bore 61 during the injection molding process, the necked-down portion of the bore acts to center the cable 59 in the bore 61 so that the resilient body 45 can surround the cable and insulate it from the bore walls. Isolating the cable 59 from the metal walls of the bore 61 prevents wear on the cable that might otherwise occur as the belt flexes while traveling around the sheaves. Once the polyethylene has been injected into the bore 61 around the cable 59, the necked-down portion at walls 62 and 63 further acts to allow the resilient body 45 to grip the drive block 60 against longitudinal motion. The necked-down portion restricts this motion since it would require the resilient block to squeeze through a smaller opening. In another alternate embodiment of the belt 20, a drive block 65 includes a bore 66 having a single beveled wall 67. The features of the belt in this alternate embodiment are identical in all other respects to the previously described embodiments. The beveled wall 67 also produces a necked-down portion of bore 66 so that a cable 64 extending through the bore isolated from the bore walls and the drive block 65 is restrained as previously described. While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.

Claims: A stone-cutting device comprising: a main frame (13); a jib (10) movably mounted to said frame; a pair of spaced apart sheaves (11, 12) rotatably mounted to said jib; means on said main frame for rotating said sheaves; and a belt (20) extending around said sheaves, said belt (20) comprising a flexible and continuous belt-shaped main body (45) with length and lateral width, said main body having a substantially flat top surface (21) and a bottom surface, said bottom surface being adapted to engage said sheaves; and a plurality of stone-cutting elements (40) mounted in said main body (45) through mounting means (19) embedded within the main body (45) and arranged in such a manner that said plurality of elements (40) are spaced along the length of the main body (45), characterized in that each of said elements (40) has a width substantially less than the lateral width of said main body (45), and a portion of each of said cutting elements (40) projects above said top surface (21) of the main body while the remainder portion of each cutting element (40) is held in the main body, wherein said cutting elements are staggered across the width of said main body in a pattern to form a continuous cutting width at least equal to the width of said main body. The stone-cutting device of claim 1, wherein: said main body (45) of said belt (20) is of a resilient material; and said stone-cutting elements (40) each include a poly-crystalline diamond cutting tooth. The stone-cutting device of claim 2, wherein said belt (20) includes at least one flexible elongated member (30) extending along the length thereof and entirely embedded in said resilient material. The stone-cutting device of claim 2, wherein: said main body (45) of said belt (20) includes laterally opposite sides; and said pattern includes: a first group (50) of said stone-cutting teeth (40) converging alternately from each of said opposite sides, wherein the lateral distance between pairs of alternate cutting teeth is less than the width of a cutting tooth, and a second group (52) of said stone-cutting teeth (40) converging alternately from each of said opposite sides and lengthwise overlapping each of said lateral distances between each of said pairs of alternate cutting teeth in said first group. A stone-cutting belt comprising: a flexible and continuous belt-shaped main body (45) with length and lateral width, said main body having a substantially flat top surface (21) and a bottom surface, said bottom surface configured to be drivenly engaged by a sheave; and means (30), extending through said main body along the length thereof, for providing belt strength, said belt comprising a plurality of stone-cutting elements (40) mounted in the main body (45) through mounting means (19) embedded within the main body (45) and arranged in such a manner that said plurality of elements (40) are spaced along the length of the main body (45), characterized in that each of said elements has a width substantially less than the lateral width of said main body (45) and that a portion of each of said cutting elements (40) projects above said top surface (21) of said main body (45), while the remainder portion of each element (40) is held in the main body, wherein said stone-cutting elements (40) are staggered across the width of said main body in a pattern to form a continuous cutting width at least equal to the width of said main body. The stone-cutting belt of claim 5, wherein: said main body (45) is of a resilient material; said means (19) for mounting each of said plurality of stone-cutting elements (40) includes a plurality of rigid blocks (24, 35) embedded in said resilient material with their top face (36) flush with the top surface (21) of said main body and spaced along the length of said main body; and said stone-cutting elements (40) each include a poly-crystalline diamond cutting tooth mounted in each of said rigid blocks (35) such that a portion of said tooth projects above said top surface (21) of said main body (45). The stone-cutting belt of claim 5, wherein said means for providing belt strength includes: at least one bore (61, 66) through each of said plurality of rigid blocks (24, 35) along the length of said main body (45), said bore including a necked-down portion generally mid-length in said bore, and at least one flexible elongated member (30, 59) extending through each of said at least one bore, wherein each of said elongated members is entirely embedded in said resilient material and is insulated from the walls of said bore (61, 66) by said resilient material. The stone-cutting belt of claim 6, wherein: said main body (45) includes laterally opposite sides; and said pattern includes: a first group (50) of said stone-cutting teeth (40) converging alternately from each of said opposite sides, wherein the lateral distance between pairs of alternate cutting teeth is less than the width of a cutting tooth; and a second group (52) of said stone-cutting teeth (40) converging alternately from each of said opposite sides and lengthwise overlapping each of said lateral distances between each of said pairs of alternate cutting teeth in said first group. The stone-cutting belt of claim 6, wherein: each of said cutting teeth (40) includes a pair of lateral faces (R, L); and opposing lateral faces (R, L) of alternate pairs (A, B) of cutting teeth in said first group (50) are coplanar with a plane extending along the length of said main body (45) such that said plane intersects one of said cutting teeth (D) in said second group (52). The stone cutting belt of claim 6, wherein: each of said rigid blocks (24, 35) includes: a top face (36) flush with the top surface (21) of said main body (45); a front face (35a) perpendicular to said top face (36) and arranged toward the direction of travel of said belt (20); a tooth slot opening (42) from said top face (36) and said front face (35a), including a back wall (43) opposite said opening (42) in said front face, said back wall (43) being sloped away from the direction of travel of said belt (20), said tooth slot (42) being adapted to receive a cutting tooth (40) therein.

Inventors: FISH DONALD D, FISH, DONALD D.
Applicants: MEYERS W F CO, W.F. MEYERS COMPANY, INC.
Application year: 1988
Main classification: B28D1
IPC codes: B28D1