Abstract:
A flying saw has at least one guide rail, on which a saw apparatus is mounted so as to be displaceable along a profile or pipe material to be cut to predetermined lengths, by way of at least one travel drive, particularly synchronous to the advancing movement of the profile or pipe material during cutting. The saw apparatus is disposed within a frame element that is mounted so as to be displaceable on the guide rail. The saw apparatus is releasably connected with the frame element.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    Applicant claims priority under 35 U.S.C. §119 of European Application No. 11003943.5 filed on May 12, 2011, the disclosure of which is incorporated by reference. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The invention relates to a flying saw having at least one guide rail, on which a saw apparatus is mounted so as to be displaceable along profile or pipe material to be cut to predetermined lengths, by way of at least one travel drive, particularly synchronous to the advancing movement of the profile or pipe material during cutting. 
         [0004]    2. The Prior Art 
         [0005]    So-called flying saws, which are synchronized with the advance of the profile or pipe section and undertake the cutting process in accordance with the advance of the profile or pipe section, are used for cutting profiles or pipe sections welded along a longitudinal seam, which sections are theoretically endless. Such flying saws, as they are known, for example, from German Patent Application No. DE 31 12 519 A1, comprise a saw apparatus that is disposed so as to be movable within a machine bed. For this purpose, guide and drive elements are disposed in the machine bed. Generally, a rack and pinion drive is disposed in the machine bed to move the saw apparatus along the machine bed. 
         [0006]    Such flying saws are used, for example, in pipe production facilities in which metal sheets continuously shaped into pipes are welded, which are subsequently sawed to predetermined lengths by way of the flying saw. Because a shut-down of such facilities has significant monetary effects, shut-down times must be restricted to a minimum. It is a disadvantage of the previously known flying saws that repairs or even tool changes take significant amounts of time, thereby causing high costs. 
       SUMMARY OF THE INVENTION 
       [0007]    It is therefore an object of the invention to provide a flying saw in which maintenance-related and repair-related shut-down times are minimized. According to the invention, this object is accomplished by a flying saw, having at least one guide rail, on which a saw apparatus is mounted so as to be displaceable along profile or pipe material to be cut to predetermined lengths, by way of at least one travel drive. The drive is particularly synchronous to the advancing movement of the profile or pipe material during cutting. The saw apparatus is disposed within and releasably connected to a frame element that is mounted so as to be displaceable on the at least one guide rail. 
         [0008]    The saw apparatus according to the invention minimizes shut-down times indicated by maintenance and/or repair work. By means of the placement of the saw apparatus within a frame element, in such a manner that the apparatus is releasably connected with the frame element, replacement of the saw apparatus within the frame element is made possible. The actual maintenance and/or repair work can be undertaken after the saw apparatus of the flying saw has been replaced; operation can be continued immediately with the replaced saw apparatus. 
         [0009]    In a further development of the invention, at least one guide rail as well as the at least one travel drive is disposed above the saw apparatus, whereby in particular, no machine bed is present. As a result, effort-minimized production is made possible. Furthermore, contamination of the drive, which is usually disposed in a machine bed, by cooling fluid and chips is avoided. Complicated production of a machine bed is eliminated. 
         [0010]    In an embodiment of the invention, two guide rails are provided, which accommodate at least one transverse support that can be displaced on them, thereby forming a portal on which the frame element that accommodates the saw apparatus is disposed. In this way, reliable suspension of the frame element that accommodates the saw apparatus is achieved. 
         [0011]    In a further embodiment of the invention, the saw apparatus can be moved within the frame element by way of at least one drive. In this way, alignment of the saw apparatus relative to the profile or pipe material to be cut to length is made possible. 
         [0012]    In a further development of the invention, the saw apparatus is connected with the frame element by way of a displacement device, by way of which the saw apparatus can be moved vertically within the frame element. In this connection, the displacement device preferably comprises a spindle that is connected with a spindle drive. 
         [0013]    Alternatively, a hydraulically or pneumatically operated telescoping rod can be provided. In this connection, it is advantageous if the displacement device is configured so that the saw apparatus can be brought out of the frame element by way of the displacement device. 
         [0014]    In an embodiment of the invention, the saw apparatus is releasably connected with the spindle by way of a coupling. It is advantageous if the coupling is configured so that it can be locked and unlocked electrically, pneumatically, or hydraulically. In this way, simple release of the connection after the saw apparatus has been brought out of the frame element, as well as simple connection after a saw apparatus has been accommodated in the frame element, are made possible. 
         [0015]    In a further embodiment of the invention, the frame element can be moved horizontally along the at least one transverse support by way of a drive. In this way, horizontal alignment of the saw apparatus is made possible. 
         [0016]    In a further embodiment of the invention, at least one vertical guide is present within the frame element, by way of which guide the saw apparatus is connected with the frame element. In this way, guided vertical movement of the saw apparatus within the frame element is made possible. 
         [0017]    In a further embodiment of the invention, a lifting apparatus is provided, whereby a positioning device is disposed on the frame element, which device allows coupling of the lifting apparatus in a defined position, for removal of the saw apparatus from the frame element. In this way, it is made possible to bring the saw apparatus out of the frame element, into the lifting apparatus, and/or to transfer a saw apparatus that has been made available on the lifting apparatus for introduction into the frame element. 
         [0018]    In a further embodiment of the invention, the lifting apparatus has at least one vertical guide that corresponds with the vertical guide of the frame element and that forms a continuation of the vertical guide of the frame element in the coupled position of the lifting apparatus. In this way, threading of the saw apparatus into the vertical guide of the frame element is facilitated, thereby bringing about time-optimized replacement of a saw apparatus using the lifting apparatus. It is advantageous if the lifting apparatus is configured to be displaceable, for installation or removal of the flying saw. 
         [0019]    In a further embodiment of the invention, the saw apparatus is formed by a whirling cutting apparatus. In this way, an effective cutting process for cutting profile or pipe material to length is made possible. Furthermore, such a whirling cutting apparatus can be implemented in a compact manner, thereby making it possible to reduce centrifugal forces and to optimize acceleration processes. 
         [0020]    In a further development of the invention, at least one clamping module for accommodating a profile or pipe material to be cut to length is provided, which module is connected with the transverse support and can be set against the saw apparatus. In this way, a modular structure is achieved, in which the clamping module can be moved or replaced independent of the saw apparatus, thereby improving accessibility to the saw tool, for example, and facilitating its replacement due to wear. It is advantageous if such a clamping module is provided on both sides of the saw module, in each instance, in the direction of the sections. The pipe material to be cut to length can thereby be fixed in place on both sides of the saw tool, in the clamping modules. In this case, it is possible to set the clamping modules very close to the saw tool, thereby making it possible to reduce vibrations during the sawing process. 
         [0021]    By means of the separate, modular configuration of the clamping module, a more compact construction of the saw apparatus is brought about, thereby simplifying replacement of the saw apparatus in the flying saw. 
         [0022]    In a further embodiment of the invention, the at least one clamping module is connected with at least one separate transverse support, by way of which it can be displaced on the at least one guide rail. In this way, setting the clamping module against the saw apparatus is simplified. Furthermore, simple removal of the at least one clamping module from the saw apparatus is made possible, thereby improving accessibility to the tool of the saw apparatus for tool replacement. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]    Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention. 
           [0024]    In the drawings, wherein similar reference characters denote similar elements throughout the several views: 
           [0025]      FIG. 1  shows the schematic representation of a flying saw having two saw apparatuses, in a top view; 
           [0026]      FIG. 2  shows the schematic representation of a saw apparatus of the flying saw from  FIG. 1 ; 
           [0027]      FIG. 3  shows the schematic representation of a saw apparatus from  FIG. 2  in a side view, and 
           [0028]      FIG. 4  shows the schematic representation of a clamping module of the saw apparatus from  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0029]    Referring now in detail to the drawings, the flying saw selected as the exemplary embodiment essentially consists of a rail system  1  on which a transverse support  2  is disposed in a displaceable manner, which support accommodates an interchange frame  3  for accommodating a whirling cutting apparatus  4 . A clamping module  5  for a clamping profile or pipe material to be cut in place is disposed on both sides of the whirling cutting apparatus  4 . A chip conveyor  6  for carrying away chips and cooling fluid is disposed underneath the whirling cutting apparatus  4 . 
         [0030]    The rail system  1  is formed from pillars  11  disposed parallel to one another, on which two supports  12 , disposed parallel to one another, are attached. In the exemplary embodiment, the pillars  11  are screwed to a support profile  81  that is cast into a foundation  8 . A rail  13  for displaceable contact of the transverse supports  2  is disposed along each of the supports  12 . A pinion rack  14  is disposed on each support  12 , on the outside, parallel to the rails  13 . 
         [0031]    The transverse supports  2  are formed by two supports  21  disposed transverse to the supports  12 , which are connected with one another by way of two profiles  22  disposed along the supports  12 , so that a rectangular frame is formed. A guide  23  for engagement with the rails  13  of the rail system  1  is disposed underneath each of the profiles  22 , on them. A servo-drive  24  is disposed at each of the two ends of a support  21 , the drive axle of which is provided with a gear wheel  241 , which engages into a pinion rack  14  of the rail system. The transverse supports  2  can be moved along the rails  13  of the rail system  1  by way of the servo-drives  24 . In the exemplary embodiment, the transverse supports  2  are configured identically for the whirling cutting apparatuses and for the clamping modules  5 . 
         [0032]    An interchange frame  3  is attached to two transverse supports  2  by way of horizontal guide rails  311 . The interchange frame  3  is formed by a support framework  31  on which two lateral supports  32  are disposed opposite one another. In this connection, the support framework  31  is connected with a horizontal linear drive  312 , by way of which horizontal movement of the interchange frame  3  relative to the transverse supports  2  is made possible. Vertical lateral guides  321  for displaceable accommodation of the whirling cutting apparatus  4  are disposed on each of the lateral supports  32 , on their sides that face the lateral support  32  disposed to lie opposite. Furthermore, a spindle  33  is disposed on the support framework  31 , which spindle can be driven by way of a spindle drive  321  and is connected with the whirling cutting apparatus  4  by way of a coupling  332 . In the exemplary embodiment, the coupling  332  is configured so that it can be locked and unlocked hydraulically. The whirling cutting apparatus  4  can be shifted along the vertical lateral guides  321 , along the lateral supports  32 , by way of the spindle  33 . 
         [0033]    Whirling cutting apparatuses for cutting pipe-shaped and rod-shaped work pieces are known, for example, from European Patent No. EP 490 328 B1. A whirling method is a chip-removing method in which the tool moves around the work piece in the manner of a spiral whirl. The cutting depth is produced by one or more blades that circulate at high cutting speed, in a single work step. In this connection, the inner mantle surface formed by the cutting tool rolls on the cylindrical outer mantle surface of the work piece to be machined. This movement process is superimposed on the constantly circulating movement of the cutting tool. The whirling method has the advantage that a plurality of cutting tools, particularly cutting blades, can be disposed next to one another and engage the work piece at the same time, over a greater segment region. In this connection, during whirling cutting, a whirling saw tool having teeth that lie on the inside is used. The cutting teeth of the whirling tool can penetrate into the work piece tangentially. Because of the whirling method, the effective penetration radius of the whirling tool only has to comprise the wall thickness of the work piece. If this involves solid material, the whirling tool only has to penetrate to the center point of the solid material, because the other half of the work piece is cut off by the circular movement of the whirling tool. The whirling cutting apparatus  4  has an integrated drive  41 . In the exemplary embodiment, the drive is configured as an electromagnetic rotational direct drive. 
         [0034]    In the exemplary embodiment, positioning bores  332  are furthermore disposed at the free ends of the lateral supports  32 . The positioning bores  332  serve for precise positioning of a displaceable lifting apparatus—not shown—that is provided with lateral guides that correspond with the lateral guides  321  of the lateral supports in the set-on position, in such a manner that the whirling cutting apparatus  4  can be moved into the lateral guides of the lifting apparatus by way of the spindle  33 , and can subsequently be uncoupled from the spindle. Simple replacement of the whirling cutting apparatus  4  is made possible by means of such a lifting apparatus. For positioning, positioning aids disposed on the lifting apparatus are introduced into the positioning bores, so that a precisely positioned connection between lifting apparatus and the lateral supports is achieved. For simplification of the threading process, positioning bores and positioning pins can also be configured to be conical. The movement of the saw apparatus  4  into the lateral guides of the lifting apparatus takes place by way of the spindle  33 . When the saw apparatus  4  is resting on the lifting apparatus, the coupling  332  can be released and the saw apparatus  4  can be removed. Equipping the flying saw with a saw apparatus  4  takes place analogously, in the reverse order. 
         [0035]    A clamping module  5  for clamping the profile or pipe material to be cut to length in place is disposed on both sides of the whirling tool  42  accommodated by the whirling cutting apparatus  4 , on each of two transverse supports  2 . The clamping module  5  is formed by a console  50  connected with the transverse supports  2 , which console accommodates three clamping jaws  51  disposed offset by 120°, which jaws can be pressed against a pipe  7  to be clamped in place, by way of hydraulic cylinders  52 . Furthermore, a roll guide—not shown—is provided as a seat for the rod or pipe material to be cut to length. The roll guide—not shown—essentially comprises conical rolls that are set against one another, on which the rod or pipe material to be cut to length is disposed in displaceable manner. The clamping modules  5  are releasably connected with two transverse struts  54 , by way of hydraulic locking mechanisms  53 , which struts are attached on the two transverse supports  2  that accommodate the interchange frame  3 . The clamping modules  5  can be released from the transverse struts  54  by means of hydraulic unlocking, and displaced separately along the rails  13  of the rail system  1 . In the exemplary embodiment, the clamping modules  5  are configured to be identical and are disposed on both sides of the whirling cutting apparatus, as mirror images of one another. 
         [0036]    Accordingly, while only a few embodiments of the present invention have been shown and described, it is obvious that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.