Abstract:
An apparatus for grinding and polishing without visible flaws a variety of different size and shape full-lead crystal workpieces. A conveyor supports the workpieces and runs through the apparatus housing. A workpiece calibrator is located proximate the entrance end of the housing. A plurality of grinders having an abrasive grinding surface within a range of coarseness are located downline of the calibrator. A plurality of polishers are located downline of the grinders. Control means raises and lowers the calibrator, grinders and polishers relative to the belt conveyor and the unfinished surface of the workpiece supported thereon. A method of automatically making a finished full-lead crystal ornament using an automated machine having a housing, conveyor, a plurality of motor-driven grinding heads, and a plurality of motor-driven polishing heads. The unfinished lead-crystal blank is oriented on the conveyor such that an unfinished work surface of the blank is unobstructed by and extends outwardly from the conveyor. The grinding heads and polishing heads are calibrated to a predetermined location relative to the conveyor and the unfinished work surface of the blank. The work surface is ground by each of the succeeding grinding heads having a less coarse abrasive grinding surface and then polished by each of the next succeeding polishing heads. The blank is reoriented on the conveyor so that a different unfinished work surface is unobstructed by and extends from the conveyor. The grinding and polishing steps are then repeated on each unfinished work surface.

Description:
This is a continuation of prior application Ser. No. 09/146,626 filed Sep. 3, 1998 now U.S. Pat. No. 6,152,809. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to an automated method and apparatus for cold-end processing full-lead crystal. More particularly, the invention relates to an automated method and apparatus for grinding and polishing full-lead crystal ornaments, figurines, trophies, and the like. 
     BACKGROUND OF THE INVENTION 
     Cold-end processing of full-lead crystal workpieces such as decorative ornaments, figurines, trophies, or the like (hereinafter “ornaments”) is a very labor intensive industry. To make a full-lead crystal ornament, craftsmen first rough cut, carve or grind the ornament from a slab of full-lead crystal. The slabs, when provided from the material manufacturer, typically weigh about 15-60 pounds depending on the specific finished product, and have dull, uneven, unpolished surfaces. 
     After the ornament is rough cut or carved from the slab, each surface must be ground and polished to a clear, brilliant finish. In the prior art, each surface is first hand ground three times with a progressively finer grinding surface. Each surface is then hand polished three times with a progressively finer polishing surface. This six step grinding/polishing process must be performed on each outer surface of the ornament. 
     Since the process of cold-end finishing full-lead crystal ornaments is very labor intensive, automation of even a portion of the finishing process would significantly reduce the overall cost of the ornament. It is estimated that the cost of cutting, grinding and polishing the ornament comprises at least about 80 percent of the ornament&#39;s factory cost whereas the cost of the lead-crystal material comprises no more than about 20 percent of the factory cost. Therefore, it would be desirable to reduce the amount of hand labor involved in cold-end finishing full-lead crystal ornaments in order to reduce the overall cost of the ornament. 
     Some industries teach automated machines for grinding and/or polishing materials having significantly different properties than full-lead crystal. For example, in the marble and granite industry, the Mantello honing machine, Officina Meccanica Antonino Mantello, Catania, Italy, is known for polishing the face surface of large marble or granite workpieces. In the plate glass industry, the Bovone straight line edging machine, Bovone Elettromeccanica, Belforte Monferrato, Italy, is known for edge finishing sheets of plate glass having a material thickness in the range of 2 mm to 25 mm. While the Mantello honing machine and the Bovone edge finishing machine provide a finished surface which is acceptable for marble, granite, and plate glass, respectively, the Mantello honing machine (in its original unmodified condition) cannot provide the clear, brilliant surface finish required for full-lead crystal ornaments and the Bovone straight line edging machine does not have the widthwise capacity to process common full-lead crystal ornaments. Therefore, it would also be desirable to provide an automated apparatus and method capable of providing a finish which is clear and brilliant enough for full-lead crystal, i.e., without visible flaws. 
     SUMMARY OF THE INVENTION 
     The present invention provides a system of automated apparatus for cutting, beveling, grinding, and polishing, the flat, outer surfaces of full-lead crystal ornaments to a finish which is clear and brillant, and without visible flaws. One apparatus of the system automatically grinds and polishes the large flat face surfaces of a full-lead crystal workpiece. Another apparatus automatically bevels, grinds and polishes the edge surfaces of a full-lead crystal workpiece. Another apparatus automatically cuts intricate shapes in the workpiece. 
     The face surface finishing apparatus has a housing, a conveyor for carrying the workpiece through the housing, a calibrator, a plurality of grinders, a plurality of polishers, and control means for raising and lowering the calibrator, grinders, and polishers relative to the conveyor and the workpiece supported thereon. The calibrator, grinders and polishers are located above the conveyor belt. 
     The conveyor preferably includes a horizontal, variable-speed, endless-belt conveyor running lengthwise downline through the housing from the entrance end to the exit end. The conveyor also includes a pair of unpowered, roll conveyors, one located proximate the entrance end and the other located proximate the exit end of the belt-conveyor. 
     The calibrator is located proximate the entrance end of the housing. The calibrator has a leading, abrasive cutting surface which course grinds the workpiece to a desired thickness. Preferably, the calibrator abrasive cutting surface has a coarseness in the range of about 30 grit to about 50 grit. 
     The grinders are located downline from the calibrator. Each of the grinders has a motor and a grinding head having an abrasive grinding surface within a range of coarseness, preferably in the range of about 60 grit to about 800 grit. The grinding heads comprise a circular base plate having replaceable grinding pads releasably attached to the base plate. The grinders are arranged sequentially downline within in the housing in an order of decreased coarseness. 
     The polishers are arranged downline from the grinders within the housing. Each of the polishers has a motor and a polishing head having a coarseness in the perforated pad range. The polishing heads preferably comprise a circular base plate having replaceable polishing pads. The polishing heads are used in conjunction with a polishing compound, preferably cerium oxide. 
     The control means raises and lowers the calibrator head, grinding heads and polishing heads relative to the conveyor and the unfinished surface of the workpiece supported by the conveyor. The control means also sequentially lowers and raises each of the grinding heads and polishing heads into contact with the workpiece being conveyed downline on the conveyor. 
     Lubricating fluid nozzles are located around the calibrator head, polishing heads, and grinding heads. The nozzles are connected to a separate sources of lubricating fluid and polishing and direct the flow of fluid onto the unfinished surface of the workpiece during grinding and polishing. A valve controls the flow of fluid through each of the nozzles. A collection basin is located underneath the housing for collecting and recycling the fluid emitted from the nozzles. A dryer is located proximate the exit end of the housing for removing residual fluid from the workpiece. 
     The edge surface finishing apparatus has a housing, a conveyor for carrying the workpiece through the housing, a plurality of grinders, a plurality of polishers, and control means for raising, lowering and tilting the grinders and polishers relative to the conveyor and the workpiece supported thereon. 
     The conveyor includes a processing conveyor comprising a pair of opposed, vertically-oriented, variable-speed, endless-belt conveyors running lengthwise downline through the housing from the entrance end to the exit end. The processing grasps or “sandwiches” the face surfaces of the workpiece and suspends the unfinished edge surface oriented downwardly. The processing conveyor has means for adjusting the distance between the belts to accomodate a variety of workpieces having different thicknesses. 
     The conveyor also includes horizontal load and unload belt conveyors located in line with the entrance end and the exit end of the processing conveyor. The entrance end load conveyor “feeds” workpieces into the edge surface finishing apparatus. The exit end unload conveyor “removes” workpieces from the edge surface finishing apparatus. 
     The grinders and polishers are located underneath the vertical belt conveyor. Each of the grinders has a motor and a grinding head having an abrasive grinding surface within a range of coarseness, preferably in the range of about 60 grit to about 800 grit. The grinders are arranged sequentially downline within the housing in an order of decreased coarseness. 
     The polishers are arranged downline from the grinders within the housing. Each of the polishers has a motor and a polishing head having a coarseness in the felt pad range. The polishing heads preferably comprise a circular base ring having replaceable polishing felt pads. The polishing heads are used in conjunction with a polishing compound, preferably cerium oxide. 
     The control means raises, lowers and tilts the grinding heads and polishing heads relative to the processing conveyor and the unfinished edge surface of the workpiece supported by the processing conveyor. The control means positions the grinding heads and polishing heads so that each of the heads properly contacts the bottom surface of the workpiece as processed by the preceding head. 
     Lubricating fluid nozzles are located around each of the polishing heads and grinding heads. The nozzles are connected to separate sources of lubricating fluid and polishing fluid, and direct the flow of fluid onto the unfinished surface of the workpiece during grinding and polishing. A valve controls the flow of fluid through each of the nozzles. A collection basin is located underneath the housing for collecting and recycling the fluid emitted from the nozzles. 
     The cutting apparatus comprises a high-pressure fluid cutting machine such as an Ingersoll-Rand® Waterjet cutting machine. 
     The present invention also provides an automated method of cutting, beveling, grinding, and polishing, full-lead crystal ornaments using one or more of the finishing apparatus described above. An unfinished lead-crystal workpiece is oriented on a conveyor such that a first work surface of the workpiece is unobstructed by and extends outwardly from the conveyor. The workpiece is conveyed over a series of progressively finer grinding heads and polishing heads which are positioned relative to the conveyor and the unfinished work surface of the workpiece. The work surface is simultaneously lubricated with a fluid during grinding and polishing. 
     After the first work surface is ground and polished, the workpiece is reoriented on the conveyor so that a Liv different unfinished work surface is unobstructed by and extends from the conveyor. The above-described grinding and polishing steps are repeated until each of the desired work surfaces are finished. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic illustration of the full-lead crystal automatic processing system in accordance with an embodiment of the invention; 
     FIG. 2 is a schematic illustration of a face surface finishing apparatus in accordance with an embodiment of the invention; 
     FIG. 3 is a side elevation of a calibrater head in accordance with an embodiment of the invention; 
     FIG. 4 is a top plan view of a grinding head in accordance with an embodiment of the invention; 
     FIG. 5 is a side elevation of the grinding head shown in FIG. 4; 
     FIG. 6 is an enlarged plan view of a replaceable grinding disc of the grinding head shown in FIG. 4; 
     FIG. 7 is a side elevation of the replaceable grinding pad shown in FIG. 6; 
     FIG. 8 is a schematic illustration of an edge surface finishing apparatus in accordance with an embodiment of the invention; 
     FIGS. 9 a  and  b  are schematic illustrations of the workpiece suspended by a conveyor shown in relation to a grinding head of the edge surface finishing apparatus of FIG. 8; 
     FIG. 9 c  is an enlarged fragmented side elevation of a workpiece showing various unfinished work surfaces; 
     FIG. 10 is a perspective view of a sample full-lead crystal ornament made in accordance with an embodiment of the invention; 
     FIG. 11 a - 11   d  are perspective views of a workpiece during intermediate processing steps. 
     FIGS. 12-17 are examples of full-lead crystal ornaments made using the apparatus and method of the present invention. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     The present invention is described below with reference to FIGS. 1-17 wherein like reference numerals are used throughout to designate like elements. 
     The cold-end, full-lead crystal processing system of the present invention is illustrated schematically in FIG.  1  and is designated generally be reference numeral  10 . The system comprises a plurality of specialized surface finishing apparatus. One apparatus  20  is constructed and arranged for grinding and polishing large flat face surfaces of an unfinished full-lead crystal workpiece  12 . Another apparatus  100  is constructed and arranged for grinding and polishing the elongate, flat edge surfaces of a full-lead crystal workpiece  12 . Yet another apparatus  200  is constructed and arranged for precision cutting intricate patters in a full lead-crystal workpiece  12 . The apparatus  20 ,  100 , and  200  are each self-contained units. In a preferred embodiment, the system comprises several edge surface finishing apparatus  100   a ,  100   b ,  100   c , each of which is specially designed to handle different sizes of workpiece  12 . The components  20 ,  100   a ,  100   b ,  100   c ,  200  may be remotely located from one another or connected by powered roller conveyors  14  which convey the workpiece  12  from one apparatus to another. The system  10  may also include means for reorienting the workpiece as the workpiece is conveyed from one component to another. Such means may include robotic arms  300  which releasably grasp and rotate the workpiece. 
     The face surface finishing apparatus  20  is described in greater detail with reference to FIGS. 2-7. The face surface finishing component  20  is designed primarily to automatically grind and polish large flat slabs which are then cut into smaller pieces for further processing. However, the face surface finishing apparatus may also be used to grind and polish the flat face surfaces of a large dimensional piece of full-lead crystal (ornament). 
     The face surface finishing apparatus  20  has a housing  22  with an entrance end  22   a  and an exit end  22   b . A conveyor system supports and carries workpieces  12  downline from a loading area, through the housing  22 , and out to an unload area. The conveyor system comprises a load conveyor  25  leading from the load area to the housing entrance, an unload conveyor  27  leading from the housing exit end to the unload area, and a processing conveyor  24  extending through the housing intermediate the load and unload conveyors. The processing conveyor  24  is preferably a variable-speed, horizontally-oriented, endless-belt conveyor  24  located within and extending the length of the housing  22 . The load and unload conveyors are preferably unpowered, roller conveyors located in line with the processing conveyor  24  proximate the entrance end  22   a  and exit end  22   b , respectively, of the housing  22 . 
     The workpieces should be loaded onto the load conveyor  25  with the unfinished work surface facing up. The load conveyor  25  is preferably not powered so that the workpiece  12  may be pushed forward onto the belt conveyor  24  and abutted with a previously loaded workpiece  12  to form a contiguous series of individual workpieces  12 . The workpieces  12  should preferably be loaded in a contiguous, abutting configuration so that the grinding/polishing lubricating fluid (described below) flows from the top surface of one workpiece to the top surface of another workpiece. 
     The face surface finishing component  20  has a calibrator  26 , a plurality of grinders  28 , and a plurality of polishers  30 , respectively, arranged in-line within the housing  22  above the processing conveyor  24 . The calibrator  26  course grinds the workpieces  12  to a desired thickness. The grinders  28  and polishers  30  then automatically grind and polish the surface with progressively finer heads until the workpiece attains a brilliant finish. 
     The calibrator  26 , grinders  28   a - 28   d  and polishers  30   a - 30   c  each have a rotating head  32 ,  34   a - 34   d ,  36   a - 36   c , respectively, which is driven by a separate electric motor,  38   a ,  38   b - 38   e ,  38   f - 38   h , respectively. In the embodiment illustrated in FIG. 2, the calibrator motor is variable speed and generates about 10 h.p. while the grinding and polishing motors are single speed and generate about 5.5 h.p. Each of the motors rotate at about 500 revolutions per minute. 
     The calibrator includes an actuator  50   a  which raises and lowers the calibrator grinding head  32  relative to the processing conveyor  24  and the workpiece  12  supported thereon. The grinders  28  and the polishers  30  also have actuators  50   b - 50   e ,  50   f - 50   h , respectively, which raise and lower the grinding and polishing heads  34   a - 34   d ,  36   a - 36   c , respectively, relative to the processing conveyor  24  and the workpiece  12  supported thereon. In a preferred embodiment, the actuators  50   b - 50   e ,  50   f - 50   h  comprise hydraulic pistons which provide an upward lifting force to disengage the polishers and grinders from the workpiece. To engage the workpiece, the hydraulic pistons are released or “bled” so that gravity pulls the grinders and polishers into contact with the workpiece. Preferably, the hydraulic pistons do not apply a downward force to increase the pressure of the grinding or polishing heads. Rather, pressure between the grinding and polishing heads and the workpiece is created only by the weight of the grinders and polishers. 
     Each actuator  50  is connected to a controller  52   b - 52   h . The controllers  52  sequentially lower each of the grinders heads and polishers into contact with the first workpiece being conveyed downline on the conveyor. After the last workpiece is conveyed downline, the actuators sequentially lift the grinders and polishers so that. they do not fall onto the conveyor belt. 
     A calibrator head  32  is shown in greater detail in FIGS. 3 and 4. The calibrator head base plate  44  has an annular, grinding ring  46  fixed to one side proximate the outer perimeter of the base plate  44 . The grinding ring  46  may be made from an abrasive material such as diamond in a bronze bond. The base plate  44  has a series of apertures  48  proximate the inner perimeter through which fasteners are inserted for mounting the calibrator head  32 . Since the calibrator is designed to initially remove large amounts of material from the slab/workpiece  12 , the grinding ring  46  has a very rough surface, preferably 30-50 grit, and has a tapered leading edge  46   a  to cut into the leading edge of the slab/workpiece  12 . In a preferred embodiment, the calibrator head  32  is about  14  inches in diameter. 
     A grinding head  34  is shown in greater detail in FIGS. 5-7. The circular base plate  56  has a plurality of replaceable, grinding pads  58  removably fixed thereto. The grinding pads may be made from an abrasive material such as diamond in a metal bond to diamond in a resin bond. The base plate  56  has a series of apertures  60  proximate both the inner and outer perimeter through which fasteners are inserted for mounting the grinding head  35 . In a preferred embodiment, the base plate is approximately 14 inches in diameter. 
     The replaceable grinding pads  58  are arranged in a radial pattern around the outer perimeter of the base plate  56 . The replaceable pads  58  have a trapezoidal shape as best seen in FIG.  6 . The grinding pads  58  have a tapered leading grinding surface as best seen in FIG.  7 . In a preferred embodiment, the grinding pads are glued to the base plate  56  which is bolted to the grinding head. 
     Lubricating fluid nozzles  64  are located around the head of the calibrator  32 . Lubricating fluid nozzles are also located around each grinding head  34  and each polishing head  36 . The nozzles proximate the calibrator head  32  and the grinding heads  34  are connected to a lubricating fluid source  40   a  through a control valve  42   a - 42   e . The lubricating fluid is preferably water and is supplied to each head at a rate of about 4.1 gallons per minute. The nozzles  64  direct the lubricating fluid onto the top surface of the workpiece  12  during grinding. The lubricating fluid runoff is-collected in a basin  66   a  located underneath the processing conveyor  24 . Preferably, the lubricating fluid runoff is recycled to the lubricating fluid source  40   a  after removing any grinding residue contained therein. 
     As shown by fluid flow lines in FIG. 6, lubricating fluid is dispersed from a lubricating fluid nozzle through the center of a grinding head and is dispersed radially outwardly across the work surface of the workpiece. 
     The nozzles proximate the polishing heads  36  are connected to a polishing fluid source  40   b  through control valves  42   f - 42   h . The polishing fluid is preferably a water and cerium oxide mixture and is supplied to each head at a rate of about 2.1 gallons per minute. The nozzles  64  direct the fluid onto the top surface of the workpiece  12  during polishing. The fluid runoff is collected-in a basin  66   b  located underneath the processing conveyor  24 . Preferably, the lubricating fluid runoff is recycled to the polishing fluid source  40   b  after removing any grinding residue contained therein. The basins  40   a  and  40   b  are segregated to prevent the lubricating fluid from mixing with the polishing fluid. 
     A forced air dryer  68  is located proximate the exit end of the belt conveyor  24 . The dryer  68  operates at about 3.7 kilowatts cubic feet per minute. The dryer  68  removes any residual fluid on the workpiece  12  so that a workman can safely carry the workpiece back to the front of the face surface finishing apparatus  20  for another surface finishing pass, or to another component  100  at a different work station. 
     The apparatus  20  is preferably designed to handle large, flat workpieces up to 12 inches wide and ¾ to 5 inches thick. Workpieces less than about ¾ inches thick should preferably be temporarily fixtured before processing in the apparatus  20 . 
     In operation, the workpieces  12  are initially loaded onto the load conveyor  25  in an abutting arrangement. The belt conveyor  24  carries and supports the workpiece through the apparatus  20 . The top surface of the workpiece  12  is automatically ground and polished to the desired thickness, dried, and conveyed to the unload conveyor. If another surface on the workpiece requires finishing, the workpieces  12  are sent through the apparatus  20  once again. In a preferred embodiment, the total processing time for one surface is about 20 minutes. 
     The edge surface finishing apparatus  100  is described in greater detail with reference to FIGS.  8 , 9  and  9   a . The edge surface finishing component  100  automatically grinds and polishes the elongate, edge surfaces of the workpiece. The edge surface finishing apparatus  100  can grind and polish a flat edge surface perpendicular to the face surface. The apparatus can also grind and polish a flat edge surface transverse to the face surface, i.e., provide a bevelled edged. The apparatus  100  can grind and polish large crystal slabs which are then cut into smaller pieces for further processing. The apparatus can also grind and polish large or small dimensional pieces of full-lead crystal (ornaments). 
     The edge surface finishing component  100  has a housing  122  with an entrance end  122   a  and an exit end  122   b . A conveyor system supports and carries one or more workpieces  12  downline through the housing  122 . The conveyor system comprises a load conveyor  125 , an unload conveyor  127 , and a processing conveyor  124  intermediate the load and unload conveyors. The processing conveyor  124  is preferably a pair of opposed variable-speed, vertically-oriented, endless-belt conveyors located within and extending the length of the housing  122 . Referring to FIG. 9, the belt conveyors  124  grasp or “sandwich” the workpiece on its opposed face surfaces  12   a ,  12   b , thereby leaving its bottom edge surface  12   c  unobstructed by the conveyor belts  124 . The distance between the opposed conveyor belts  124  is adjustable for grasping workpieces within a range of thicknesses. 
     The load  125  and unload  127  conveyors are preferably powered, belt conveyors located in line with the processing conveyor  124  proximate the entrance end  122   a  and exit end  122   b , respectively, of the housing  122 . The workpiece is oriented on the load conveyor  125  such that the edge surface to be beveled/finished  12   c  is oriented face down. The workpiece  12  is conveyed forward by the load conveyor  125  and grasped by the processing conveyor  124 . The processing conveyor  124  carries the workpiece  12  through the apparatus  100  and delivers the finished workpiece to the unload conveyor  127 . 
     The edge surface finishing component has a plurality of grinders  128  and a plurality of polishers  130  arranged in-line within the housing  122  underneath the processing conveyor  124 . The grinders  128  and polishers  130  automatically grind and polish the surface with progressively finer heads until the workpiece attains the desired shape and finish. 
     The grinders  128   a - 128   j  and polishers  130   a - 30   d  each have a rotating head  134   a - 134   j ,  136   a - 136   d , respectively, which is driven by a separate electric motor,  138   a-j ,  138   k - 138   n , respectively. In the embodiment illustrated in FIG. 8, the motors generate about 2.7 horsepower and rotate at about 1000 revolutions per minute. 
     An actuator  150  raises, lowers and tilts the grinders  128  and polishers  130  relative to the processing conveyor  124  and the unfinished work surface of the workpiece  12  supported thereon. Each actuator  50  is connected to a controller  154  which controls the linear and angular position of each grinder  128  and polisher  130  relative to the processing conveyor  124  and the unfinished work surface of the workpiece supported thereon. 
     The grinders  128  and polishers  130  are mounted on rocker assemblies  153  which allow the grinders  128  and polishers  130  to be rotated about the unfinished work surface of the workpiece  12 . For example, referring to FIG. 9 b , the first grinder  128   a  can be rotated relative to the workpiece  12  to change the bevel angle between the grinding head  134   a  and the face surface  12   b.    
     The number of grinders  128  and polishers  130  can be varied to meet the specific needs of the operator. For example, in the embodiment illustrated in FIGS. 8 and 9, the apparatus has 10 grinders and 4 polishers. In other embodiments, the apparatus has 7 grinders and 3 polishers; in a further embodiment, the apparatus has 13 grinders and 4 polishers. 
     The grinders  128  and polishers  130  are preferably arranged in sets which are constructed and arranged to grind and polish a specific edge surface of the workpiece  12 . In the  14  head edge finishing apparatus shown in FIG. 8, the first four grinders  128   a - 128   d  are designed to coarse grind the bottom surface  12   c  of the workpiece. The fifth grinder  128   e  is designed to coarse grind a small bevelled edge or seam  12   d  on the front surface. The sixth grinder  128   f  is designed to coarse grind a small bevelled edge or seam  12   e  on the back surface. The seventh and eighth grinders  128   g ,  128   h  fine grind the bottom surface  12   c . The ninth grinder  128   i  fine grinds the back seam  12   d . The tenth grinder  128   j  fine grinds the front seam  12   e . The first polisher  130  fine polishes the front seam  12   d . The second polisher  130   b  fine polishes the back seam  12   e . The third and fourth polishers  130   c ,  130   d  fine polish the bottom surface  12   c . The function and coarseness of each grinder and polisher is summarized below in Table I. 
     
       
         
               
             
               
               
               
             
           
               
                 TABLE I 
               
             
             
               
                   
               
               
                 Fourteen-Head Edge Finishing Apparatus 
               
             
          
           
               
                 ELEMENT/HEAD 
                 FUNCTION 
                 COARSENESS 
               
               
                   
               
               
                 Grinder 1 (128a) 
                 Coarse grind bottom edge (12c) 
                 30-50 
               
               
                 Grinder 2 (128b) 
                 Coarse grind bottom edge (12c) 
                 30-100 
               
               
                 Grinder 3 (128c) 
                 Coarse grind bottom edge (12c) 
                 220 
               
               
                 Grinder 4 (128d) 
                 Coarse grind bottom edge (12c) 
                 400 
               
               
                 Grinder 5 (128e) 
                 Coarse grind front seam (12d) 
                 110 
               
               
                 Grinder 6 (128f) 
                 Coarse grind back seam (12e) 
                 110 
               
               
                 Grinder 7 (128g) 
                 Fine grind bottom edge (12c) 
                 400 
               
               
                 Grinder 8 (128h) 
                 Fine grind bottom edge (12c) 
                 600 
               
               
                 Grinder 9 (128i) 
                 Fine grind back seam (12d) 
                 400 
               
               
                 Grinder 10 (128j) 
                 Fine grind front seam (12e) 
                 400 
               
               
                 Polisher 1 (130a) 
                 Fine polish front seam (12d) 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                 Polisher 2 (130b) 
                 Fine polish back seam (12e) 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                 Polisher 3 (130c) 
                 Fine polish bottom edge (12c) 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                 Polisher 4 (130d) 
                 Fine polish bottom edge (12c) 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                   
               
             
          
         
       
     
     Grinder head nos.  1 ,  2 ,  3 ,  5  and  6  are diamond in a resin bond. Grinder head nos.  4 ,  7 ,  8 ,  9  and  10  are diamond in a resin bond. The polishes are used in conjunction with a cerium oxide mixture. 
     In a preferred embodiment, the fourteen-head edge finishing apparatus  100   b  comprises a Bovone  14  straight line edging machine modified in accordance with the teachings of the present invention. 
     A seventeen-head edge finishing apparatus  100   c  is summarized below in table II. The apparatus  100   c  has additional grinding and polishing wheels which are specifically designed to grind and polish large bevelled edges on the front or back face of the workpiece  12 . In a preferred embodiment, the seventeen-head edge finishing apparatus  100   c  comprises a Bovone  17  straight line edge finishing machine which has been modified in accordance with the teachings of the present invention. 
     
       
         
               
             
               
               
               
             
           
               
                 TABLE II 
               
             
             
               
                   
               
               
                 Seventeen-Head Edge Finishing Apparatus 
               
             
          
           
               
                 ELEMENT/HEAD 
                 FUNCTION 
                 COARSENESS 
               
               
                   
               
               
                 Grinder 1 
                 Coarse grind bottom edge or 
                 30-50 
               
               
                   
                 primary bevel 
               
               
                 Grinder 2 
                 Coarse grind bottom edge or 
                 80-110 
               
               
                   
                 primary bevel 
               
               
                 Grinder 3 
                 Coarse grind bottom edge or 
                 220-320 
               
               
                   
                 primary bevel 
               
               
                 Grinder 4 
                 Fine grind bottom edge or 
                 320-400 
               
               
                   
                 primary bevel 
               
               
                 Grinder 5 
                 Fine grind bottom edge or 
                 600-800 
               
               
                   
                 primary bevel 
               
               
                 Polisher 1 
                 Fine polish bottom edge or 
                 Polishing 
               
               
                   
                 primary bevel 
                 felt 
               
               
                 Grinder 6 
                 Course grind bottom 
                 110 
               
               
                 Grinder 7 
                 Coarse grind front seam 
                 110 
               
               
                 Grinder 8 
                 Coarse grind back seam 
                 110 
               
               
                 Grinder 9 
                 Fine grind bottom 
                 320-800 
               
               
                 Grinder 10 
                 Fine grind bottom 
                 320-800 
               
               
                 Grinder 11 
                 Fine grind back seam 
                 320-800 
               
               
                 Grinder 12 
                 Fine grind front seam 
                 320-800 
               
               
                 Polisher 2 
                 Fine polish fron seam 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                 Polisher 3 
                 Fine polish back seam 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                 Polisher 4 
                 Fine polish bottom edge 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                 Polisher 5 
                 Five polish bottom edge 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                   
               
             
          
         
       
     
     Grinder head nos.  1 ,  2 ,  3 ,  6 ,  7  and  8  are diamond in a metal bond. Grinder head nos.  4 ,  5 ,  9   10 ,  11  and  12  are diamond in a resin bond. The polishers are used in conjunction with a cerium oxide mixture. 
     A ten head edge finishing apparatus  100   a  is summarized below in Table III. 
     
       
         
               
             
               
               
               
             
           
               
                 TABLE III 
               
             
             
               
                   
               
               
                 Ten-Head Edge Finishing Apparatus 
               
             
          
           
               
                 ELEMENT/HEAD 
                 FUNCTION 
                 COARSENESS 
               
               
                   
               
               
                 Grinder 1 
                 Coarse grind front bevel 
                  30-50 
               
               
                 Grinder 2 
                 Coarse grind front bevel 
                  80-100 
               
               
                 Grinder 3 
                 Coarse grind front bevel 
                 220-310 
               
               
                 Grinder 4 
                 Fine grind front bevel 
                 320-800 
               
               
                 Grinder 5 
                 Fine grind front bevel 
                 320-800 
               
               
                 Grinder 6 
                 Fine grind front bevel 
                 320-800 
               
               
                 Grinder 7 
                 Fine grind front bevel 
                 320-800 
               
               
                 Polisher 1 
                 Fine polish front bevel 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                 Polisher 2 
                 Fine polish front bevel 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                 Polisher 3 
                 Fine polish front bevel 
                 Polishing 
               
               
                   
                   
                 felt 
               
               
                   
               
             
          
         
       
     
     A grinding head  134  is shown in greater detail in FIG. 9 c . The griding head  134   a  includes a grinding wheel  134   b  on which an abrasive material or felt  134   c  is mounted. The grinding head  134   a  is mounted on a spinning shaft  134   d  connected to a motor  134   e  having a collar  134   f  around the shaft  134   d . The grinding heads may be made from an abrasive material such as diamond in a metal bond or resin bond. In a preferred embodiment, the grinding heads are approximately 6 inches in diameter. 
     A lubricating fluid nozzle  164  is located proximate each grinding head  134  and each polishing head  136 . The nozzles  164   a-j  proximate the grinding heads are connected to a lubricating fluid source  140   a  through a control valve  142   a - 142   j . The lubricating fluid is preferably water and is supplied to each head at a rate of about 4.1 gallons per minute. The nozzles  164  direct the lubricating fluid onto the bottom edge surface and bevelled edge surfaces of the workpiece  12  during grinding. The lubricating fluid runoff is collected in a basin  166   a  located at the bottom of the housing  122  underneath the processing conveyor  124 . 
     The nozzles  164   k-n  proximate the polishing heads are connected to a polishing fluid source  140   b  through a control valve  142   k - 142   n . The polishing fluid is preferably a water and and cerium oxide mixture and is supplied to each head at a rate of about 2.1 gallons per minute. The nozzles  164  direct the polishing fluid onto the bottom edge surface and bevelled edge surface of the workpiece  12  during polishing. The polishing fluid run off is collected in a basin  166   b  located at the bottom of the housing  122  underneath the processing conveyor  124 . Preferably both the lubricating fluid and the polishing fluid are recycled to the lubricating fluid source  140   a  and polishing fluid source  140   b  respectively, after removing any residue contained therein. The basins  140   a  and  140   b  are segregated to prevent the lubricating fluid from mixing with the polishing fluid. 
     The ten-head apparatus  100   a  is designed to handle workpieces up to 25 mm thick. The fourteen-head apparatus  100   b  is designed to handle workpieces up to 55 mm thick. The seventeen-head apparatus is designed to handle workpieces up to 60 mm thick. 
     In operation, the workpieces  12  are initially loaded onto the load conveyor  125  with the unfinished edge surface facing down. The workpiece  12  is then conveyed into the processing  124  which carries and supports the workpiece through the apparatus  100 . The bottom surface of the workpiece  12  is automatically ground and polished to the desired thickness and shape, including bevelled surfaces, and conveyed to the unload conveyor. If another surface on the workpiece requires finishing, the workpiece  12  is sent through the apparatus  100  once again. In a preferred embodiment, the total processing time for one surface is about 6-10 minutes depending on the particular ornament and machine on which the ornament is processed. 
     The cutting apparatus  200  is preferably a water jet cutting machine sold by, for example, Ingersoll-Rand. The cutting apparatus  200  automatically cuts intricate shapes in the workpiece  12  using a concentrated stream of high-pressure fluid. 
     One of ordinary skill in the art should recognize that the above-described apparatus  20 ,  100   a ,  100   b , and  100   c  can be used in a wide variety of sequences to automatically cold-end finish full-lead crystal ornaments of almost endless variety. A first example of cold-end processing in accordance with the present invention is described with reference to FIGS. 10 and 11 a - 11   d.    
     FIG. 10 illustrates a full-lead crystal ornament which may be presented to, for example, a retiring employee of a company. The ornament has an enlarged, flat front  112   a  and back  112   b , a bevelled, top front surface  112   c , an elongate, top  112   d  and bottom  112   e  surface, and a flat right  112   f  and left  112   g  side surface. 
     In one method, an elongate crystal slab is loaded into the face surface finishing apparatus  20 . As seen in FIG. 11 a , the all six outer surfaces of the slab are unfinished (as indicated by dots) including the top surface which has chill wrinkle (as indicated by wavy lines). The bottom and top surfaces of the slab are ground and polished (as shown by stars) in the apparatus  20  to the dimensions shown in FIG. 11 b . The bottom and top polished surfaces of the slab will become the front  112   a  and back  112   b  face surfaces of the ornament. 
     The slab shown in FIG. 11 b  is then cut to the dimensions shown in FIG. 11 c  corresponding to the length L of the ornament. Each unfinished edge surface is then ground and polished using one or more of the edge surface finishing apparatus  100 . The apparatus  100  also grinds and polishes the bevelled surface  112   c  at the same time the top surface  112   d  is being ground and polished. Finally, inscription is applied to the face surface using known techniques. 
     Further examples of full-lead crystal ornaments processed in accordance with the present invention are illustrated in FIGS. 12-18. Each of the ornaments shown in FIGS. 12-18 are copyrighted designs by Crystal Signatures, Inc. 
     FIGS. 12 a  and  12   b  illustrate an ornament entitled “City Bar” having a thickness T of 37 mm., a width W of 4.5 in., and a height H of 7.5 in. 
     Initially, the front  212   h  and back  212   i  face surfaces are processed. A full-lead crystal slab of approximately 40 mm.×10 in.×22 in. is passed through the face surface finishing apparatus  20  at least two times, once for each face surface. Additional passes may be required if the slab is warped or uneven. Both face surfaces  212   h ,  212   i  of the slab are ground and polished to a thickness of 37 mm. The slab is then cut by a diamond saw to the rough dimensions of the final ornament. 
     The edge and bevel surfaces are then processed. The workpiece is first processed through the 14-head edge surface apparatus  100   b  to grind and polish the bottom surface  212   a . The workpiece  212  is then processed through the 17-head apparatus  100   c  three times to grind and polish the remaining surfaces. In the first pass, the top surface  212   b  and the top bevel  212   c  are simultaneously ground and polished. In the second pass, the right side surface  212   d  and the right side bevel  212   e  are simultaneously ground and polished. In the third pass, the left side surface  212   f  and the left side beveled surface  212   g  are simultaneously ground and polished. The ornament is now completely finished and ready for personalization or shipment. 
     FIGS. 13 a  and  13   b  illustrate an ornament entitled “Tower” having a thickness T of 2 in., a width W of 2 in., and a height H of 8.5 in. 
     Initially, the front  312   a  and back  312   b  face surfaces are processed. A full-lead crystal slab approximately 50-55 mm.×10 in.×22 in. is processed through the face surface finishing apparatus  20  at least two times, once for each face surface. Additional passes may be required if the slab is warped or uneven. Both face surfaces of the slab are ground and polished to a thickness of 2 in. The slab is then cut into strips of approximately 52 mms. wide×22 in. long using a diamond saw. 
     The edge and bevel surfaces are then processed. The workpiece is processed through the 14-head edge surface apparatus  100   b  to grind and polish the remaining surfaces. In the first pass, the left side surface  312   c  is ground and polished. In the second pass, the right side surface  312   d  is ground and polished. The workpiece strips are then cut on an angle to create the top bevel surface  312   e  to the rough dimensions of the final ornament. The workpiece is then processed through the 14-head apparatus  100   b  for two more passes to grind and polish the top bevel surface  312   e  and the bottom surface  312   f.    
     FIGS. 14 a  and  14   b  illustrate theme placque ornaments entitled “Eagle” and “Flag”, respectively. The ornaments  412 ,  512  have a thickness of 19 mm., a width W of 6 in., and a height H of 3.5 in. 
     Initially, the front and back face surfaces are processed. A full-lead crystal slab approximately 19-20 mm.×10 in.×22 in. is processed through the face surface finishing apparatus  20  at least two times, once for each face surface. Additional passes may be required if the slab is warped or uneven. Both face surfaces of the slab  412   a ,  412   b ,  512   a , and  512   b  are ground and polished to a thickness of 19 mm. 
     The slabs are then cut with the programmable water jet machines  200  into the shapes shown in FIGS. 14 a  and  14   b . The workpieces are then processed through the 14-head edge surface finishing apparatus  100   b  to grind and polish the right side  412   c ,  512   c , and the bottom surface  412   d ,  512   d . Finally, a graphical region  412   e ,  512   e  is masked and sandblasted to create a graphical design on the ornament. 
     FIGS. 15 a  and  15   b  illustrate an ornament entitled “Obelisk” having a thickness T of 2 in., a width W of 4 in., and a height H of 15 in. 
     Initially, the front  612   a  and back  612   b  face surfaces are processed. A full-lead crystal slab approximately 55-57 mm.×10 in.×22 in. is processed through the face surface finishing apparatus  20  at least two times, once for each face surface. Additional passes may be required if the slab is warped or uneven. Both face surfaces of the slab are ground and polished to a thickness of 2 in. 
     The edge surfaces are then processed. The workpiece is processed through the 14-head edge surface apparatus  100   b  to grind and polish the top  612   c , bottom  612   d , left side  612   e  and right side  612   f.    
     The bevel surfaces are then processed. The workpiece is processed through the 17-head edge surface apparatus  100   c  to grind and polish the left  612   g  and right  612   h  front bevel surfaces and the left  612   i  and  612   j  back top bevel surfaces. The workpiece is fixtured at the desire angle as it passes through the 17-head surface apparatus  100   c.    
     FIGS. 16 a  and  16   b  illustrate an ornament entitled “Super Bevel Sculpture” having a thickness T of 2 in. a width W of 4.75 in., and a height H of 9.5 in. 
     Initially, the front  712   a  and back  712   b  face surfaces are processed. A full-lead crystal slab 55-57 mm.×10 in.×22 in. is processed through the face surface finishing apparatus  20  at least two times, once for each face surface. Both face surfaces of the slab are ground and polished to a thickness of 2 in. The slab is then cut by a diamond saw to the rough dimensions of the final ornament. 
     The edge surfaces are then processed. The workpiece is processed through the 14-head edge surface apparatus  100   b  to grind and polish the top  712   c , bottom  712   d , right  712   e , and left  712   f  side surfaces of the ornament. 
     The bevel surfaces are then processed. The workpiece is processed through the 17-head edge surface apparatus  100   c  to grind and polish the multiple beveled surfaces on the front and back. 
     FIGS. 17 a ,  17   b  and  17   c  illustrate an ornament entitled “Trapezoid” having a thickness T of 37 mm., a width W of 5 in., and height H of 6.75 in. 
     Initially, the front  812   a  and back  812   b  face surfaces are processed. A full-lead crystal slab 40-44 mms.×10 in.×22 in. is processed through the face surface finishing apparatus at least two times, once for each face surface. Both face surfaces of the slab are ground and polished to a thickness of 37 mm. The polished slab is then cut by a diamond saw to the rough dimensions of the final ornament. 
     The top  812   c  and bottom  812   d  surfaces are then processed. The workpiece is processed through the 14-head edge surface apparatus  100   b  to grind and polish the top  812   c  and bottom  812   d  surfaces. 
     The bevel surfaces  812   e ,  812   f  are then processed. The workpiece is processed through the 17-head edge surface apparatus  100   c  to grind and polish the left bevel  812   e  and the right bevel  812   f.