Patent Publication Number: US-10328607-B2

Title: Machine for cutting stone material

Description:
RELATED APPLICATIONS 
     This application is a 35 U.S.C. 371 national stage filing from International Application No. PCT/IB2015/058494, filed Nov. 3, 2015, which claims priority to Italian Application No. 202015000010860, filed Apr. 2, 2015 and Italian Application No. TV2014A000154, filed Nov. 3, 2014, the teachings of which are incorporated herein by reference. 
     The present invention relates to a machine for cutting stone material. 
     In particular, the present invention relates to a machine for cutting natural stone, agglomerate, ceramic or glass material. 
     In the continuation of the present description reference will be made to the cutting of slabs of natural stone and agglomerate, ceramic and glass material, without however this being intended to limit the possible materials which may be machined. The machining of other materials may also be carried out by a machine designed in accordance with the principles of the present invention. 
     The machines which are preferably used for this type of machining comprise a machining head which is moved above a workpiece support bench. The means used to move the machining head may comprise various alternatives, but among these the most common solution comprises two lateral support structures on which a beam is arranged transversely with respect thereto. 
     The beam is adapted to slide on the lateral support structures via guiding means provided on the lateral support structures and on the ends of the beam. 
     A sleeve-holder carriage is arranged on the beam and is adapted to slide along the beam in a transverse direction with respect to the lateral support structures. 
     A sleeve is provided on the sleeve-holder carriage and may be moved relative to the sleeve-holder carriage in a vertical direction towards or away from the workpiece support bench. 
     The end of the sleeve is provided with a machining head having a spindle on which a cutting disk is mounted. 
     The workpiece support bench and/or the spindle are adapted to rotate about respective vertical axes so as to be able to adjust in any direction the cutting disk with respect to the slab to be cut. 
     The cutting disks used are of the diamond type and are provided with a protection element for the operator, mounted on the cutting spindle. The element provides on the one hand protection against possible detachment of diamond segments from the disk. Furthermore, it is also adapted to contain and retain any spray of the cooling fluid used during cutting of the slab and containing machining residue. 
     It is also known to provide devices for moving the slabs, or parts of a slab obtained therefrom, above the workpiece support bench. These devices may be of a different type and have different forms. 
     The devices which have been found to be most advantageous comprise sucker means provided on the head or on the protection element. 
     In a particular configuration, these sucker means are provided on the external surface of the protection element, with an operating surface which lies substantially parallel to the plane in which the cutting disk lies. In other words, the gripping surface of the sucker means is substantially parallel to the cutting direction. 
     In these machines, after performing the cut, and when it is required to move a slab or part thereof, the spindle is rotated through approximately 90° about an axis which is substantially parallel to the plane in which the workpiece support bench lies, and in such a way that the operating surface of the sucker means is substantially parallel to the surface of the slab to be moved. 
     The sucker means, whether they be attached to the head or to the protection element, are moved closer by means of a vertical movement of the sleeve until they come into contact with the slab to be moved. 
     At this point a vacuum circuit, which is connected to the interior of the sucker means, is activated and in this way gripping between the sucker means and the workpiece is ensured. 
     The workpiece may then be moved away from the other workpieces being machined so that for example a successive machining operation may be completed. 
     Once displacement has been completed, the workpiece is released and the sucker means may be used to move another slab part or a slab, or, by means of a rotation in a direction opposite to that of the preceding rotation, the spindle is repositioned so that the cutting disk assumes again a position substantially perpendicular to the workpiece support bench. 
     The rotation about a horizontal axis (parallel to the plane in which the workpiece support bench lies) may be used also to perform cuts inclined in a manner known per se to the person skilled in the art. 
     The slab may also be cut according to different patterns, for example a chequer-board pattern, or according to more complex patterns if the machine is equipped with means for moving the pieces of cut material. 
     Machines having the aforementioned characteristics are described for example in Italian patent application TV2009A000189, in international patent application WO2011/145005 and in Italian patent 1402232. 
     The machines of the prior art, although widely used and popular, are not without drawbacks. 
     In fact, for example the productive capacity of this type of machine, although significant, is however limited. 
     The prior art has attempted to solve these drawbacks in various ways, for example by installing two machines, but this means doubling the costs to be incurred. If it is also considered that each machine is often associated with a system for loading slabs and unloading the finished articles so as to form an actual production line, the cost needed to duplicate such a line reaches a very high and on occasions unacceptable figure. 
     Moreover it must also be considered that the additional space required to install the second machine or rather the second line may occupy a large area of the production plant. It could also happen that there is not sufficient space and therefore it becomes impossible to acquire a second machine/line, thus ruling out the possibility of increasing the production capacity. 
     The object of the invention is therefore to solve at least partially the drawbacks of the prior art. 
     A first task of the present invention is to provide a machine which is able to obtain the advantages which could be achieved with the installation of a second machine. 
     A second task of the present invention is to increase substantially the production capacity of a machine of the type described above, but at the same time without increasing the costs significantly thereof. 
     A further task of the present invention is to provide a machine which is able to increase the production, while maintaining substantially unchanged the space occupied by the machine inside the production plant. 
     The object and tasks are achieved with a machine according to claim  1 . 
     In particular the proposed solution is that of providing a machine for cutting slabs, comprising a workpiece support bench adapted to support at least one slab, two lateral support structures and a first beam adapted to move along the lateral support structures. The first beam is adapted to slide on the lateral support structures via its ends and guiding means provided on the lateral support structures. The first beam is provided with a first carriage which is adapted to be moved along the first beam. A first sleeve adapted to be moved towards or away from the workpiece support bench is provided on the first carriage. A first machining head comprising a first cutting spindle is provided on the first sleeve. The machine is characterized in that it comprises a second beam adapted to move along the lateral support structures. The second beam is adapted to slide on the lateral support structures via its ends and guiding means provided on the lateral support structures. The second beam is provided with a second carriage which is adapted to be moved along the second beam. A second sleeve adapted to be moved towards or away from the workpiece support bench is provided on the second carriage. A second machining head comprising a second cutting spindle is provided on the second sleeve. The machine is also characterized in that at least either one of the first head and the second head is provided with a gripping device for the slabs or parts thereof. 
     The gripping device may be provided directly on the head or provided on the disk protection element. 
     The cutting disks are adapted to work simultaneously on the slab, in order to reduce to a minimum the machining time. 
    
    
     
       The characteristic features and advantages of a machine according to the present invention will become clearer from the description below of possible embodiments, provided solely by way of a non-limiting explanation, with reference to the accompanying drawings, in which: 
         FIG. 1  shows in schematic form a side view of a machine according to the present invention in a possible working configuration; 
         FIG. 2  shows a top plan view of the machine according to  FIG. 1 , in a different working configuration; 
         FIG. 3  shows in schematic form a side view of a machine according to the present invention, in a particular working configuration; 
         FIG. 4  shows in schematic form a top plan view of the machine according to  FIG. 1 , in a possible working configuration. 
         FIG. 5  shows a front view of the machine according to  FIG. 4 ; 
         FIGS. 6 and 7  show in schematic form two alternative embodiments of the present invention; 
         FIG. 8  shows in schematic form a top plan view of a machine according to the present invention in a possible working configuration; 
         FIG. 9  shows in schematic form a top plan view of the machine according to  FIG. 8 , in a different working configuration; and 
         FIG. 10  shows in schematic form a side view of the machine according to  FIG. 8 , which simulates a possible working configuration. 
     
    
    
     In  FIG. 1  the reference number  12  denotes a machine for cutting slabs according to the present invention. 
     The machine  12  comprises a workpiece support bench  14  adapted to support at least one slab, and cutting means for automated cutting of slabs. 
     The cutting means comprise two lateral support structures  16 ,  18  and a first beam  20  adapted to move along said lateral support structures  16 ,  18 . 
     The workpiece support bench  14  may be fixed or rotating. In the case where the workpiece support bench  14  is rotating, it is adapted to orient in different directions a slab being machined. 
     With reference for example to the embodiments of the present invention shown in  FIGS. 1 and 2 , the lateral support structures  16 ,  18  may be side walls. 
     In accordance with an alternative embodiment of the present invention, the lateral support structures  16 ,  18  may be structures obtained by means of beams. 
     In both cases the lateral support structures  16 ,  18  must allow sliding of at least one beam  20  on top of them and in a position situated over the workpiece support bench. 
     As can be seen in  FIGS. 1 and 2 , the first beam  20  is adapted to slide on the lateral support structures  16 ,  18  via its ends  22 ,  24  and guiding means  25 ,  26  provided on the lateral support structures  16 ,  18 , respectively. 
     In this connection the ends  22 ,  24  may be provided with travel wheels (not shown) which are moved by a suitable drive unit (not shown). The guiding means  25 ,  26  may be for example guides or guiding profiles on which the travel wheels may run. 
     In accordance with an alternative embodiment, the ends  22 ,  24  may be provided with idle travel wheels, adapted to run along guiding means comprising for example guiding profiles, and the beam may be driven by means of a rack-pinion device or a screw/worm device. Advantageously, the screw may have an extension substantially parallel to one or both the lateral support structures  16 ,  18 . 
     A first carriage  28 , adapted to be moved along the first beam  20 , is provided on the first beam  20 . Since the movement of the first carriage  28  may per se be easily imagined by the person skilled in the art, it will not be further described. 
     A first sleeve  30  adapted to be moved towards or away from the workpiece support bench  14  is provided on the first carriage  28 . 
     The first sleeve  30  is provided with a first machining head  32  comprising a first cutting spindle  34 . 
     Advantageously, the first spindle  34  is provided with a first electric motor  36  for rotation of a first diamond disk  38 . 
     Since the diamond disk is an element known per se to the person skilled in the art it will not be further described. 
     The cutting means further comprise a second beam  201  adapted to move along said lateral support structures  16 ,  18 . 
     The second beam  201  is adapted to slide on the lateral support structures  16 ,  18  via its ends  221 ,  241  and guiding means  26  provided on the lateral support structures  16 ,  18 . Advantageously, the second beam  201  uses the same lateral structures and the associated guides along which the two ends of the first beam  20  travel. 
     Advantageously, the movement of the first beam  20  is independent of the movement of the second beam  201 . In other words, each beam  20 ,  201  is provided with its own movement means. 
     The ends  221  and  241  of the second beam  201  may be of the same type as the ends  22  and  24  of the first beam. 
     Advantageously the first beam  20  may be parallel to the second beam  201 . 
     A second carriage  281  is provided on the second beam  201  and is adapted to be moved along the second beam  201 . A second sleeve  301  is provided on the second carriage  281  and is adapted to be moved towards or away from the workpiece support bench  14 . 
     A second machining head  321  comprising a second cutting spindle  341  is provided on the second sleeve  301 . 
     Advantageously, the second spindle  341  is provided with a second electric motor  361  for rotation of a second diamond disk  381 . 
     In accordance with a possible embodiment of the present invention, at least either one of the first cutting spindle  34  and second cutting spindle  341  is provided with a protection element  40 ,  401 . 
     In accordance with the preferred embodiment of the present invention, shown in the attached figures, both cutting spindles  34 ,  341  are provided with a common protection element  40 ,  401 . 
     The machining heads  32 ,  321  may comprise means for rotation of the cutting spindles  34 ,  341  about an axis substantially parallel to the plane in which the workpiece support bench lies. The axis of rotation is visible in  FIG. 1  and also in  FIG. 5  and is indicated by the reference number  46 ,  461 . In this particular embodiment of the present invention it is therefore possible to perform cuts inclined with respect to a direction substantially perpendicular to the plane in which the workpiece support bench lies. 
     The present invention envisages that at least either one of the first head  32  and the second head  321  is provided with a gripping device  42 ,  421  provided directly on the head or provided on the disk protection element. 
     Advantageously, both the heads  32 ,  321  may comprise a gripping device  42 ,  421 . 
     In accordance with a possible embodiment of the present invention the gripping device  42 ,  421  may be of the sucker type. 
     With reference to the particular embodiment shown in  FIG. 3 , at least one of the protection elements  40 ,  401  comprises a gripping device  42 ,  421  for moving the slabs. 
     Advantageously, both the protection elements  40 ,  401  may comprise a gripping device  42 ,  421 . 
     In accordance with a possible embodiment of the present invention the gripping device  42 ,  421  may be of the sucker type. The gripping device  42 ,  421  may comprise at least one closed sucker element  44 ,  441  adapted to rest on a slab and prevent in the contact condition fluid from flowing between the internal area and the external area. 
     A fluid connection with vacuum generating means (not shown) is provided in said internal area of the sucker element  44 ,  441 . 
     In accordance with a possible embodiment of the present invention each sucker element  44 ,  441  may be activated in an independent manner. 
     The two beams  20 ,  201  and the two cutting spindles  34 ,  341  may be similar and one or both the cutting spindles  34 ,  341  may be provided with suckers for moving the parts. 
     According to an embodiment of the present invention at least one of the sucker elements is moved closer owing to a vertical movement of the sleeve until the sucker means come into contact with the slab to be moved. At this point the vacuum generating means, which are connected to the interior of the sucker means, are activated and in this way gripping between the sucker element and the workpiece is ensured. 
     The workpiece may then be for example raised from the workpiece support bench  14 , moved away from other workpieces being machined and then placed again on the workpiece support bench so that for example a successive machining operation may be completed. 
     In this embodiment of the machine  12  according to the present invention, in which the sucker means are fixed to the disk protection element, after performing the cut and when it is required to move a slab or a part thereof, the spindle  34 ,  341  is rotated through approximately 90° about an axis  46 ,  461  substantially parallel to the plane in which the slab support bench lies of approximately 90° so that the operating surface of the sucker elements is substantially parallel to the surface of the slab to be moved. 
     Once displacement of the part has been terminated, by means of a rotation in the opposite direction to the preceding direction, the spindle is repositioned so that the diamond disk is arranged again in a position substantially perpendicular to the workpiece support bench. 
     As regards further details relating to protection elements provided with sucker elements, reference may be made to international patent application WO 2011/145005. 
       FIG. 6  shows an alternative embodiment of the gripping devices  42 ,  421 . The gripping device  42 ,  421  is provided directly on the machining head  32 ,  321  and is slidable in a vertical direction, towards or away from the workpiece support bench  14 . Advantageously in this case also, the gripping device may be of the sucker type. 
     The enlarged view of  FIG. 6  shows in continuous lines the rest configuration and in broken lines the working configuration where the gripping device is situated underneath the bottom edge of the disk. 
       FIG. 7  shows a further embodiment of the gripping device according to the present invention. In this case also the gripping device is arranged on the working head  32 ,  321 . The machining head  32 ,  321  is provided with support elements  48 ,  481  which are adapted to support two swivel gripping elements  50 ,  52 ;  501 ,  521 . In particular, the two swivel gripping elements  50 ,  52 ;  501 ,  521  swivel between a position where their operating surface lies substantially parallel to the workpiece support bench, i.e. a position underneath the bottom edge of the disk where they are adapted to grip a slab or a part thereof; and a position substantially rotated through 90° where they are not operative and the cutting disk may perform machining of the slab. Advantageously, the two gripping elements can be swivelled in opposite directions. 
     The enlarged view shown in  FIG. 7  shows in continuous lines the rest configuration and in broken lines the configuration where the gripping device is adapted to grip a slab. 
     This embodiment is particularly advantageous since the gripping devices are two in number and operated simultaneously so as to ensure a more balanced grip of the slab part to be moved. 
     In accordance with a possible embodiment of the present invention the workpiece support bench on which the slabs are placed is fixed, while the two cutting spindles are rotatable about their vertical axis. 
     The attached figures show various configurations of a machine according to the present invention. 
     For example, in  FIG. 1 , the two cutting disks are shown at the maximum possible distance from each other, are parallel to each other and are positioned in the longitudinal direction (parallel to the beam). 
     In  FIG. 2 , the two beams are moved as close together as possible with the two cutting disks facing each other and positioned in the longitudinal direction. 
     In  FIG. 3 , the two cutting disks are rotated through 90° compared to  FIG. 1  and therefore are still parallel to each other, but arranged transversely (at right angles to the beam). 
     In  FIGS. 4 and 5 , the two beams have been moved as close together as possible with the two cutting disks facing each other and positioned in the transverse direction. 
     In order to be able to carry out as many cuts as possible using simultaneously both the spindles  34 ,  341 , it is required to reduce the distance between the two spindles both in the direction transverse to the two beams and in the longitudinal direction of the beam. 
     In this connection it should be noted that according to a possible embodiment, the two cutting spindles  34  and  341  are mounted projecting both towards the inner side of the machine so that the minimum distance between the two cutting disks  38 ,  381  is the minimum possible with the facing disks arranged both longitudinally ( FIG. 2 , disks parallel to the beam) and transversely ( FIG. 4 , disks at right angles to the beam). 
     In particular, in  FIG. 4  it can be noted that the two spindles  34 ,  341  may be rotated in opposite directions: one in one direction and the other in the opposite direction so that the two disks may be facing each other reducing the distance between them as far as possible. 
     Advantageously, both the sleeves  30 ,  301  are arranged on the inner side of the machine so as to face each other. 
     In order to optimize the cutting cycles, in the case where cuts parallel to each other must be performed (e.g. when it is required to cut the slab into strips), it is possible to operate with both the cutting disks  38 ,  381  positioned parallel to each other. 
     If parallel cuts must be performed in the transverse direction (at right angles to the beam  20 ,  201 ), owing to the fact that the two cutting disks  38 ,  381  may be positioned parallel to each other, but facing each other (see  FIG. 4 ), it is possible to start the cut for both the disks  38 ,  381  at the same instant and terminate it again at the same instant, thus halving exactly the cutting time compared to that of a cut performed with a conventional machine. 
     Owing to these particular features, by operating using the two disks simultaneously, it is possible to perform the greatest number of cuts, using at the same time both the spindles  34 ,  341 . Advantageously, the entire cutting operation for any slab may be performed using again the two spindles  34 ,  341  simultaneously. 
     Moreover, if both the heads are provided with sucker gripping means, not only the two cutting disks  38 ,  381  are able to cut simultaneously, but also the suckers of the two heads are adapted to work simultaneously. 
     The machine may be provided with a programmable control unit for managing the movement axes of the machine. The control unit may be adapted to implement an automatic program for optimizing cutting of a slab, depending on the form and dimensions of the slab to cut and the cuts to be performed. The control unit may therefore be adapted to define autonomously the cutting sequence of each spindle and the sequence for pick-up and displacement of the material by the at least one gripping device, in order to minimize the time required to cut the entire slab, avoiding any risk of collision between the moving parts. 
     In this way, the slab cutting times are practically halved compared to those of a conventional machines, using a machine having a cost which is only slightly higher than that of a conventional machine. 
       FIGS. 8 to 10  show an alternative embodiment of the machine according to the present invention in which two machining units are provided on each beam  20 ,  201 . 
     In particular, as can be seen from  FIG. 8 , at least two machining units each comprising a spindle  34 ,  342  suitable for mounting a cutting disk  380 ,  382  are arranged on the first beam  20 . 
     The second beam  201  is provided with at least two machining units each comprising a spindle  341 ,  343  suitable for mounting a cutting disk  381 ,  383 . 
     Each machining unit comprises a carriage  282 ;  281 ,  283  adapted to be moved along the respective beam  20 ,  201 . 
     Since the movement of the carriage  28 ,  282 ;  281 ,  283  may be easily imagined by the person skilled in the art, it will not be described further. 
     Each carriage  28 ,  282 ;  281 ,  283  is provided with a sleeve  30 ,  302 ;  301 ,  303  adapted to be moved towards or away from the workpiece support bench  14 . 
     Each sleeve  30 ,  302 ;  301 ,  303  is provided with a machining head  32 ,  322 ;  321 ,  323  comprising the respective cutting spindle  34 ,  342 ;  341 ,  343 . The sleeve may comprise means for rotating the machining head  32 ,  322 ;  321 ,  323  about a substantially vertical axis of rotation. 
     The machining heads  32 ,  322 ;  321 ,  323  may comprise means for rotating the cutting spindles  34 ,  342 ;  341 ,  343  about an axis substantially parallel to the plane in which the workpiece support bench  14  lies. In this particular embodiment, it is possible to perform cuts inclined with respect to a direction substantially perpendicular to the plane in which the workpiece support bench lies. 
     Advantageously, each spindle  34 ,  342 ;  341 ,  343  is provided with its own electric motor  36 ,  362 ;  361 ,  363  for rotation of the respective cutting disk  38 ,  382 ;  381 ,  383 . 
     Each spindle is provided with a protection element  40 ,  402 ;  401 ,  403 . 
     At least one of the machining heads is provided with a gripping device  42 ,  422 ;  421 ,  423  for the slabs or parts thereof. In the preferred embodiment each machining head is provided with a gripping device for the slabs or parts thereof. 
     The gripping device may be provided directly on the head or may be provided on the protection element  40 ,  402 ;  401 ,  403 . 
     In the preferred embodiment, the gripping device is provided on each protection element and may of the sucker type. The gripping device may comprise at least one sucker element which defines a closed space and is adapted to rest on a slab and prevent in the contact condition fluid from flowing between said closed space and the external environment. 
     A fluid connection with vacuum generating means is provided in said closed space of the sucker element. 
     In accordance with a possible embodiment of the present invention each sucker element may be activated in an independent manner. 
     The operating principle of the sucker-type gripping device was described above and will not further described. 
     According to alternative embodiments, the gripping device may be provided directly on the machining head so as to be slidable in a vertical direction, towards or away from the workpiece support bench  14 . Advantageously in this case also, the gripping device may be of the sucker type. 
     The gripping device may also be of the swivel type and provided on the machining head. In particular, support elements adapted to support two swivel gripping elements may be provided on the machining head: the two swivel gripping heads swivel between a position where their operating surface lies substantially parallel to the workpiece support bench, and are therefore able to grip a slab or part thereof, and a position substantially rotated through 90° where they are not operative and the cutting disk may perform machining of the slab. 
       FIGS. 8 to 10  show various working configurations of the machine according to the present invention. 
     In  FIG. 8  the machining units of the first beam  20  face the machining units of the second beam  201 . In particular, the cutting disks are parallel to each other. In this configuration, the machine is adapted to perform simultaneously two—so-called longitudinal—cuts in two directions parallel to the beams; since the disks are aligned in pairs on each beam, they may perform simultaneously up to two single cuts, operating potentially in two different ways:
         a single spindle of each beam is active, while the other one remains inactive positioned at one end of the beam.   both the spindles of each beam are active during the same cut, the first spindle cutting the slab over about half its thickness and the second spindle performing the cut in the residual thickness. By cutting half the thickness, the feeding speed of the two spindles is obviously doubled.       

     Longitudinal cuts consisting of a number greater than two are carried out by means of successive positioning of the beams. 
     In  FIG. 9  the machining units are facing each other in pairs in a direction perpendicular to the beams. In this configuration it is possible to perform simultaneously four cuts parallel and spaced from each other. 
     In  FIG. 10 , the machining units are positioned so that the cutting disks are perpendicular to the direction of the beams and, in this configuration also, it is possible to perform cuts similar to those described above, with two spindles—one of the first beam and one of the second beam—along a same cutting path, in two directions perpendicular to the beams. 
     In this case also, the machine may be provided with a programmable control unit for managing the movement axes of the machine. The control unit may be adapted to implement an automatic program for optimizing cutting of a slab, namely define the cutting operations depending on the form and the dimensions of the slab to cut and those to be realized. Once the cutting operations have been defined, the control unit also determines the best cutting and pick-up sequence of each spindle and displacement of the material by at least one gripping device, in order to minimize the time for cutting of the entire slab, avoiding any risk of interference between the moving parts. 
     In this way, the slab cutting times are practically halved compared to those of a conventional machine, using a machine having a cost which is only slightly higher than the cost of a machine according to the prior art. 
     The advantages which can be achieved with a machine according to the present invention are therefore now clear the person skilled in the art. 
     It is possible to provide a machine which is able to obtain the advantages which could be achieved with the installation of a second machine. 
     Moreover, it is possible to increase substantially the production capacity of a machine of the type described above, but at the same time without increasing the costs thereof significantly. 
     Finally it is possible to provide a machine which is able to increase the production, while maintaining substantially unchanged the space occupied by the machine inside the production plant. 
     The person skilled in the art, in order to satisfy specific requirements, may make modifications to the embodiments described above and/or replace the parts described with equivalent parts, without thereby departing from the scope of the accompanying claims. 
     For example, in the present invention a machine with at least two beams has been described, but the principles of the present invention may comprise a greater number of beams, for example three beams. 
     Moreover, more than two machining units may be mounted on each beam.