Abstract:
A slab shaping system includes a slab shaping device. The slab shaping device includes a cutting device and de-burring device, wherein the cutting device and the de-burring device, respectively cut and de-burr a slab. According to an embodiment, the slab shaping system may include a plurality of spaced apart slab support beams that form at least one slot therebetween. According to an embodiment, the cutting device and de-burring device may be axially-aligned. A method for operating a slab shaping system is disclosed. The method includes the steps of positioning a plurality of slab support beams on a table to form at least one slot; positioning a slab over the slab support beams; positioning a cutting device and de-burring device of a slab shaping device in axial-alignment; and cutting and de-burring the cut in the slab along a length of the at least one slot.

Description:
CLAIM TO PRIORITY 
     This application is a Divisional Patent Application of application Ser. No. 11/454,555 filed on Jun. 16, 2006, now U.S. Pat. No. U.S.7,806,029 issued on Oct. 5, 2010, which claims priority to Provisional Patent Application Ser. No. 60/691,357, filed Jun. 17, 2005, the contents of which are hereby incorporated by reference. 
    
    
     FIELD OF THE DISCLOSURE 
     The invention relates to an apparatus and method for shaping material. 
     BACKGROUND 
     Steel slabs of material are typically shaped using a variety of techniques (such as slitting, cutting, etc.) Cutting machines typically include fixed devices that must be reconfigured/replaced when the shape of the cut or the cut line change. Additionally, known cutting machines may accumulate harmful dross/waste product on or near the cutting machine during a cutting operation. As such, a need exists for an improved apparatus and method for shaping slab material that overcomes the drawbacks associated with known cutting machines/techniques. 
     SUMMARY 
     A slab shaping system includes a slab shaping device. The slab shaping device includes a cutting device and de-burring device wherein the cutting device cuts the slab and the de-burring device de-burrs the slab proximate the slab cut. According to an embodiment, the slab shaping system may include a plurality of slab support beams that form at least one slot. According to an embodiment, the cutting device and de-burring device may be axially-aligned and provides a cut and/or de-burrs the slab of material along a length of the at least one slot. 
     A method for operating a slab shaping system is disclosed. The method includes the steps of positioning a plurality of slab support beams on a table to form at least one slot, positioning a slab of material over the slab support beams; positioning a cutting device and de-burring device of a slab shaping device in axial-alignment; and providing a cut and de-burring the cut in the slab of material along a length of the at least one slot. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the disclosure will now be described, by way of example, with reference to the accompanying exemplary drawings, wherein: 
         FIG. 1  is a front view of a slab shaping system according to an embodiment wherein no slab is present; 
         FIG. 2  is a left side view of a slab shaping system according to an embodiment; 
         FIG. 3  is a top view of a slab shaping system according to an embodiment; 
         FIG. 4  is a front view of a slab shaping system according system to an embodiment wherein a slab is present; 
         FIG. 5  is a left side view of a slab shaping system according to an embodiment wherein a slab of material is positioned on the slab shaping system; 
         FIG. 6  is a top view of a slab shaping system according to an embodiment including a slab of material positioned on the slab shaping system; 
         FIG. 7A  is a front view of a slab of material and a slab shaping device of a slab shaping system according to an embodiment; 
         FIG. 7B  is an embodiment of the system of  FIG. 7A , wherein a capping toe is functionally positioned to offset the position of the slab; and 
         FIG. 8  is a top view of a slab of material and a slab shaping device of a slab shaping system according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, the preferred illustrative embodiments of the present disclosure are shown in detail. Although the drawings represent some preferred embodiments of the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated to more clearly illustrate and explain the present disclosure. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the disclosure to the precise forms and configurations shown in the drawings and disclosure in the following detailed description. 
       FIGS. 1-3  illustrate an embodiment of a slab shaping system, which is shown generally at  10 . According to the illustrated embodiment, the slab shaping system  10  includes a table  12  supported on beams  14 . The table  12  can be elevated at a distance, D, approximately equal to, for example, ten or more feet from an underlying surface, S. Among other things, the elevated distance, D, of the table  12  can provide one or more of the following benefits: (a) improved visibility for an operator/crane driver (e.g., when loading or unloading a slab of material  16 —slab  16  not shown in  FIG. 1 ) to/from the table  12 , (b) efficient removal of dross/metallic waste  11  (e.g., slag removal system is represented in  FIG. 4  by a wheeled cart  18 ) from underneath the table  12 ; and/or (c) the creation of an additional clearance underneath the table  12  for a slab de-burring device  20 , which is referred to in the art as a “spyder.” Although the slag removal system is depicted as wheeled cart  18 , any removal system including conveyor belts or the like may be used. The slab of material  16  may include, but is not limited to slab steel. However, any material capable of being cut and de-barred can be processed by the present invention. 
     According to an embodiment, each table  12  includes two or more slab support beams  22  generally extending longitudinally between cross supports  23 . Table  12  may include two or more cross supports  23  spaced between opposing end  24 ,  26  of the table  12 . According to an embodiment, the slab support beams  22  may be positioned and spaced to define one or more slots  28  that may extend partially or fully from one end  24  to the opposite end  26  of the table  12 . Slots  28  may be, for example, approximately fifteen inches wide. However, it will be appreciated that the slab shaping system  10  is not limited to a specific dimension or shape of the slots  28 . De-burring device  20  may travel adjacent, proximate, under, over or within the slot  28 . 
     The de-burring device  20  and a cutting device  32  are included as part of a slab shaping device  30 . The slab shaping device  30 , according to an embodiment, may travel fully or partially between ends  24 ,  26  of the table  12  along longitudinal table axis  13 . This travel may be accomplished by way of a track system that couples device  30  to table  12 . The slab shaping device  30  generally includes a U-shaped carriage which carries a de-burring device  20  and a cutting device  32 . Because cutting device  32  and de-burring device  20  are coupled to a common U-shaped carriage, they move in unison along longitudinal axis  13 . Referring to  FIG. 1 , the U-shaped carriage  30  includes a base body portion  75  having an upper distal end  75 ′ and a lower distal end  75 ″, a first arm  77  extending from the upper distal end  75 ′ in a first direction, and a second aim  79  extending from the lower distal end  75 ″ in the first direction. In an embodiment, the base body portion  75 , the first arm  77  and the second arm  79  form the U-shaped carriage  30  to define a slab-receiving channel  81 . Referring to  FIG. 4 , the slab  16  is arranged relative the U-shaped carriage  30  such that the slab  16  is positioned within the slab-receiving channel  81 . With reference to  FIGS. 1 and 4 , in an embodiment, the cutting device  32  is coupled to the first arm  77  and extends from the first aim  77  in a second direction that is substantially orthogonal/perpendicular to the first direction for directing the cutting device  32  toward the upper face surface  42  of the slab  16  for cutting a slit  50  through the slab  16  from the entrance face formed by the upper face surface  42  of the slab  16  to the exit face formed by the lower, support surface  47  of the slab  16 . The de-burring device  20  is coupled to the second arm  79  and extends from the second arm  79  in a third direction that is substantially orthogonal/perpendicular to the first direction for directing the de-burring device  20  toward the lower, support surface  47  of the slab  16 . In an embodiment, the third direction is substantially opposite the second direction. 
     As seen in  FIG. 4 , the cutting device  32  provides a means  33  for slitting or cutting  50  slab  16 . The slit or cut  50  may partially or fully extend into the slab  16 . The means  33  may include, but is not limited to a water saw, cutting torch, laser cutting tool, rubber wheel, or the like. According to an embodiment, cutting device  32  may, in some embodiments, be referred to as a torch and the slab shaping device  30  may, in some embodiments, be referred to as a torch carriage U-frame (TCUF). 
     As illustrated in  FIG. 4 , a shaping axis, A-A, may pass through the de-burring device  20 , cutting device  32 , and along the slit or cut  50  in the slab of material  16 . Although the illustrated embodiment may include a shaping axis, A-A, extending through the de-burring device  20  and cutting device  32 , it will be appreciated that the slab shaping system  10  is not limited to include this axial arrangement nor is it limited to include a de-burring device  20  and cutting device  32 . 
     According to an embodiment, table  12  may further include toes  34  that extend from the table  12  at a distance, T ( FIG. 1 ). One or more toes  34  can be used to assist an operator/crane driver in positioning of slab  16  on the table  12 . According to an embodiment, the toes  34  may extend to a distance, T, for example, approximately eighteen inches above a top surface of table  12 . Further, the slab shaping system  10  and associated slab shaping device  30  does not require a slab  16  to reside against one or more of the toes  34  in order for the slab shaping device  30  to cut from one end  24 ,  26  to another end  24 ,  26  along an edge  17  of the slab of the material  16 . Therefore, if desired, the toes  34  may be used primarily or solely for guiding the operator/crane driver. 
     According to an embodiment, service supply lines  39  (such as those carrying water, oxygen, gas, electricity, compressed air, or the like) may be transported along the length of the table  12 , for example, by a cable track system  37 . Further, control regulators and solenoid valves may, if desired, be located proximate the slab shaping device  30 . According to an embodiment, a “home position” of the slab shaping device  30  may permit access for maintenance purposes. If desired, numerous tables  12  can be grouped together and a common control center (“pulpit”) can be located between tables  12 . For example, according to an embodiment, a pulpit can be included between each block of four tables  12 . The pulpit can be used to house, for example, a computer terminal, printer, programmable logic controller (PLC) and/or a labeling machine. 
       FIGS. 7 and 8  illustrate, an end and top view of the slab shaping device  30 . The cutting device  32  and de-burring device  20  of the slab shaping device  30  can be adapted and configured to travel longitudinally (e.g., lengthways) along the table  12  and slab  16 . If desired, the cutting device  32  and de-burring device  20  may be rigidly located (and, if desired, permanently located) in operational communication with one another along the shaping axis, A-A, so as to be substantially in an opposing operational alignment. Accordingly, the slab shaping system  10  permits, inter alia, the ability to accurately align an associated cutting device  32  and de-burring device  20 , regardless of where a slab  16  is positioned. This alignment permits both device  32  and device  20  to travel in a substantially “perfect” line along the shaping axis, A-A. Alternatively, selected portions of the slab shaping device  30  may be manipulated by a motor  36 , such as, for example, an electric motor. Moreover, the slab shaping system  10  may include various coordinated-movement features, accomplished by using, for example, a rack  38  and pinion  40  assembly coupled to motor  36  and controlled by PLC  41 . 
     According to an embodiment, the up/down  43  and/or in/out  45  motion of slab shaping device  30  may be controlled by a PLC  41 . Motion  43  and  45  may be orthogonal. Such controlled movements of the slab shaping device  30  can, among other things, ensure that the cutting device  32  is in a desired position relative a particular surface of a slab  16  at all times during cutting. For instance, if a surface of slab  16  is bowed, the cutting device  32  may be moved up or down  43  (as it longitudinally traverses slab  16 ) to maintain a preferred cutting distance from an upper face  42  of slab  16  and also to ensure that the de-burring device  20  maintains a preferred position with respect to a lower face  47  under slab  16 . Other associated positional or relevant information can be detected by indexing arm  44  and/or laser  53  and sent to PLC  41  or any other controller, or network of controllers. If desired, an in/out  45  motion of the slab shaping device  30  can also be fully controlled by a controller, for example, PLC  41 . 
     According to an embodiment, when slab  16  is on the table  12 , the slab shaping device  30  may be moved to a “cutting and/or de-burring position.” Upon contacting an edge  17  of the slab of material  16  by a horizontal slab shaping device indexing aim  46 , the cutting device  32  and de-burring device  20  may be positioned to a desired cutting and/or de-burring position. As slab  16  is being cut, the slab shaping device  30  can travel both along the length of the slab of material  16 , and also latitudinally  45 . Latitudinal movement of device  30  allows device  30  to move parallel to an edge of slab  16  even if slab  16  is not placed parallel to toes  34 . 
     Latitudinal movement  45  of both device  32  and  20  can be accomplished through two respectively associated movement mechanisms whose movement is coordinated by a central controller (e.g. PLC  41 ). Or, alternatively, the longitudinal movement  45  of devices  32  and  20  may be accomplished by moving shaping device latitudinally  45 . These types of movement mechanisms are well-known to those skilled in the art. 
     Although the slab shaping system  10  as illustrated show one cutting device  32  and one de-burring device  20 , it will be appreciated that the slab shaping system  10  may include more than one cutting device  32  and/or more than one de-burring device  20 . For example, if more than one cutting device  32  and de-burring device  20  are included, the more than one cutting device  32  and de-burring device  20  may be arranged on the slab shaping device  30  in any desirable configuration or orientation. 
     For example, the movement between a pair of the cutting devices  32  (each with a respective, axially-aligned de-burring device  20 ) can be utilized to shape a slab of material  16 . In an embodiment, the cutting devices  32  can start cutting slab  16  at opposite ends of slab  16 . The cutting devices  32  may commence cutting slab  16  concurrently, or, in various programmable, timed patterns, towards one another over the length of slab  16 . According to an embodiment, before the cutting devices  32  contact one another (or “meet”) at a point along the length of the slab of material  16  (which can be, for example, the middle of the length of the slab of material  16 ), one of the cutting device  32  can be sufficiently retracted or withdrawn (such as by returning to a start position) to permit the other cutting device  32  to complete the desired cut. 
     According to an embodiment, the associated PLC can be an ALLEN-BRADLEY® PLC, although it will be appreciated that one or multiple other programmable logic controllers may be used. Various control parameters (inputs and outputs) must be accounted for and controlled. Some parameters may include ignition of the cutting device  32 , “seeking the slab edge,” preheat time, acceleration curves, deceleration curves, cutting device off/on, regulation of cutting speed. These parameters can be controlled by PLC  41  or in other software or hardware based controllers. 
     The slab shaping system  10  of the present invention may further optionally include any or all of the following features: (a) laser distance/position measurement systems  53  (which can, for example, measure one or more slab parameters (e.g., measure the length or surface contour of the slab  16 )), (b) On/Off control of the cutting device  32 , including those using an ignition system, (c) SPC data and, if desired, an indirect or direct connection with computer networks or computer systems (e.g., computer systems connected by digital communication network (e.g. Ethernet)); (d) emergency stop controls; (e) fully or semi-automatic system operations controlled remotely, such as by a remote-control, hand-held device, or the like; (1) various control procedures, including: (1) prohibiting an operator from cutting a slab of material  16  if data has not been sorted and properly transferred/confirmed; (2) prohibiting the slab shaping device  30  from cutting without a required identification of a slab of material  16 ; (3) prohibiting cutting of a slab of material  16  if the cutting device  32  is in a non-validated position; (4) if desired, in operation, removing slabs of material  16  from the table  12  and transferring the slabs of material  16  to outgoing cells; (5) building piles of slabs of material  16  in which all slit edges are on the same side; and (6) providing two operators for some applications. 
     Further, for quality control purposes, one or more digital video cameras  49  or other visioning devices may be positioned in connection with each cutting station. These one or more visionary devices may be stationed on moving arm  51 . Arm  51  substantially follows the exit cut line of the slab and/or the de-burring device  20  across the length of the slab of material  16  to capture, in digital video form, the image along the complete length of the slab of material  16  where the exit cut line is formed on the exit face  47  of the slab  16 . Once captured in video format, each cutting process end result can be digitized and displayed on a video monitor (e.g., in a crane operators cabin or pulpit), or transferred and/or stored on a computer network so persons can view and archive the quality and character of the slab&#39;s exit cut line. The operator can, among other things, control the speed of the video (slower or faster) as the video image collection takes place along the length of the cut. This image data allows an operator to visually inspect one or more characteristics associated with the exit slit or cut line  52  across the length of the slab  16  (such as abnormalities or imperfections) created during the cutting and/or de-burring process. If an undesirable characteristic is found by viewing the video information, a crane operator can divert that slab  16  to a slab yard area where the defect can be further inspected and/or corrected. Imperfections (as manifested by the image data) can be screened by a human operator, or various vision recognition software systems can be used to computer automate the quality screening process. 
     According to an embodiment, the digital representation of video data can be viewed by a crane operator or an operator of the system (e.g., on the floor) by way of a monitor or terminal, such as a hand-held device or a terminal screen, before or during the unloading process. If a defect is observed or detected, the associated slab of material  16  can be moved, for example, by a crane, to a nearby area for visual inspection or defect correction. Such inspection or correction may include manual means or processes. 
     Now referring to  FIGS. 7A and 7B , toes  34  have been described herein as members that are essentially fixed to table  12 . Although this arrangement is satisfactory for some applications, it may be desirable to position toes  34  along an axis  55  that is essentially parallel to a top surface of slab support beams  22 . By allowing toes  34  to be adjusted along axis  55 , the position of slab  16  can be manipulated without adjusting cutting device  32  along axis  45 . Toes  34  can be adjusted along axis  55  by any type of mechanical/hydraulic/or other actuator well-known to those skilled in the art. The movement of toes  34  along axis  55  may be controlled by one or more controllers, such as, for example, PLC controller  41 . Although mechanisms can be added to move toes  34  along axis  55 , such mechanisms add to the complexity of the overall invention. In instances where automated means to move  55  toes  34  are not practical, a similar effect can be obtained by fabricating a capping toe  57  that is designed to engage a respectively associated toe  34  ( FIG. 7B ). The capping toe  57  is adapted to positively engage toe  34  such that capping toe  57  will not be dislodged by the frictional engagement of slab  16  during normal operation. By engaging capping toe  57  to toe  34 , an offset “d” is established. Thereafter, any slab that is placed on table  12  will necessarily be displaced by a distance “d.” Thus, capping toe provides a simple but yet effective, means for offsetting a slab with respect to toe  34 . Although capping toe  57  is shown as manipulatable from the top of toe  34 , it is contemplated within the scope of this invention that capping toe  57  may be elevatable from below toe  34 . Also, capping toe  57  can be manipulatable using human intervention or, simple drive mechanisms, well-known to those skilled in the art, may be used to manipulate capping toe  57  into, and out of, its offset position. 
     The present invention has been particularly shown and described with reference to the foregoing embodiments, which are merely illustrative of the best mode or modes for carrying out the invention. It should be understood by those skilled in the art that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention without departing from the spirit and scope of the invention as defined in the following claims. It is intended that the following claims define the scope of the invention and that the method and apparatus within the scope of these claims and their equivalents be covered thereby. This description of the invention should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.