AU648175B2

AU648175B2 - Improved shaping method and apparatus

Info

Publication number: AU648175B2
Application number: AU18096/92A
Authority: AU
Inventors: Richard Harvey
Original assignee: HARVEY ROBERTS Pty Ltd
Current assignee: HARVEY ROBERTS Pty Ltd
Priority date: 1991-06-05
Filing date: 1992-06-05
Publication date: 1994-04-14
Anticipated expiration: 2012-06-05
Also published as: AU1809692A

Description

648175 P/:00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

TO BE COMPLETED BY APPLICANT Name of Applicant: HARVEY ROBERTS PTY LTD Actual Inventor(s): Address for Service: JOHN R. G. GARDNER, PO BOX 443, MUDGEERABA QLD 4213 Invention title: IMPROVED SHAPING METHOD AND APPARATUS Details of Associated Provisional Applications: Nos: PK 6499 The following statement is a full description of this invention, including the best method of performing it know to me:- THIS INVENTION relates to an improved shaping method and apparatus which has particular application to the shaping of the core or blank of a surf board or any other surf craft but which may be readily applied to the shaping of other objects.

The normal method of manufacturing surf boards or ether similar craft involves the shaping of a foam core to define the required shape of the surf board and subsequently applying fibreglpss to the shaped core to provide the craft with sufficient rigidity. In current manufacturing techniques for surf boards a particular sized relatively soft foam blank or core is chosen to suit the requirements of a particular user of the board to take into account weight and ability. The core is then shaped to requirements taking into account various curves or other shapes in the surf board core to suit certain applications.

Generally this procedure is undertaken by hand with a surf board shaper working with hand tools to provide the requisite shape in the core. After the core or blank has been shaped, it is ready for air brush art work and fibreglassing, sanding and polishing. Shaping of surf boards or like cores is a skilled and difficult task and persons to carry out this task are not readily available.

Furthermore, considerable labour costs are involved in the hand shaping of a surf board core or blank. Whilst some methods have been proposed to reduce this labour cost, for example by using a pantograph mechanism so as to allow a o transfer of shapes from a formed master blank or plug, many plugs or blanks are required to enable a suitable choice to foe 30 be presented to the customer.

The present invention aims to overcome or alleviate at least one of the above disadvantages by providing a method and apparatus for the shaping of blanks :or cores of surfboard or like craft which permits the rapid 35 and efficient manufacture of blanks with many variations in designs. Whilst the present invention is particularly oo suited to the manufacture of blanks for surf board or other surf craft, it may be readily applied to the manufacture of s7% other products. Other objects and advantages of the invention will become apparent hereunder.

With the above and other objects in view, the present invention provides a method of forming a three dimensional blank or core for a surfboard or other like watercraft from a foam block using shaping means having at least one shaping tool for removing material from said foam block, said method including the steps of supporting said foam block adjacent said shaping means, preparing a computer generated visual image representing the desired three dimensional shape of said blank or core, said three dimensional shape corresponding to a desired shape of said surfboard or other like watercraft, and operating said shaping means to position and move said shaping tool relative to said foam block in accordance with said computer 9 nerated visual image so as to remove material from said foam block and form said block into said blank or core having said desired three dimensional shape.

The shaping tool is suitably provided on one side of the foam block and moved longitudinally, transversely, and towards and away from the foam block during the forming procedure. Preferably, however, a pair of shaping tools are provided on opposite sides of the foam block for operating preferably simultaneously to remove material from •oo opposite sides thereof.

The present invention also provides apparatus for use in above method, said apparatus including computer means for generating a visual image of said desired three dimensional form of said blank or core, shaping means :o 30 including said at least one shaping tool for removing o 0* o. material from said foam block, support means for supporting •o *said foam block adjacent said shaping means, actuating means for moving said shaping tool relative to said block supporting means and a foam block held thereby, and control S 35 means for controlling said actuating means and thereby movement of said shaping tools relative to said block supporting means and foam block supported thereby, said control means controlling movement of said actuating means and shaping tools in accordance with said computer generated three dimensional desired form of said blank or core whereby said shaping tool is operative to remove material from said foam block to form said foam block into said required three dimensional form of said blank or core.

Preferably, the shaping means includes first and second opposed shaping tools and means are provided for supporting the shaping tools on opposite sides of the block supporting means for independent and relative movement towards and away from each other along a first axis.

The first and second shaping tools are suitable supported in a shaping head and means are suitably provided for supporting the shaping head for movement along a second axis orthogonal to the first axis. Preferaly, also, means are provided for supporting the block supporting means for movement along a third axis orthogonal to the first and second axes.

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*o* The block supporting means may be arranged for movement in a horizontal plane and the shaping tools of the shaping head may be supported for movement in a vertical plane. The shaping head is suitably arranged for movement normal to the direction of movement of the support means in a horizontal plane.

Alternatively, the supporting means for the block may be fixed and the shaping head arranged for movement along a third axis orthogonal to the first and second axes.

The block supporting means suitably includes a pair of spaced apart support members between which the foam block arranged to be supported, the block being adapted to be supported by a plurality of clamping fingers mounted on the support m mbers and extending inwardly therefrom to engage the block in use. Alternatively, the block supporting means may be provided with clamps which are adapted to engage opposite sides and/or ends of the block.

The support members are suitably supported in cantilever fashion and the shaping tools suitably comprise motor driven routing tools. The shaping head may includes slide means for supporting the shaping tools for slidable movement.

The present invention also provides a surfboard or other surf craft including a blank or core manufactured in accordance with the above method or using the above described apparatus.

Reference will now be made to the accompanying 0.000. drawings which illustrate a preferred embodiment of the t c'o: 30 invention and wherein:- Fig. 1 is a side elevational view of a preferred form of shaping apparatus according to the present invention; Fig. 2 is an end elevational view of the 35 apparatus of Fig. 1; Fig. 3 is a cross-sectional view showing an alternative a.-rangement for clamping the product blank in position;

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Fig. 4 is a view along line A-A of Fig. 3 showing further details of the clamping mechanism; and Fig. 5 illustrates a preferred dust extraction mechanism.

In accordance with a preferred embodiment of the invention, the preferred shape of the product is initially generated on a PC computer running a three dimensional CAI) program. This provides a visual image from any angle of the finished product on the VDU screen of the computer and/or on a printer. When the desired shape of the product has been computer generated as above a second specialised program is used to reformat the data and transmit the data to a positioning system which is used to control operation of shaping apparatus in three dimensions so as to form the desired product shape. Suitably the positioning system comprises a SMCC positioning system sold under the trade mark BALDOR which is digitally programmable from the computer terminal and used to precisely control servo motors of shaping apparatus.

The preferred form of shaping apparatus 10 is shown in Figs. 1 and 2 and includes a base 11 upon which is mounted a shaping head 12 comprising first and second opposed shaping tools 13 each of which preferably comprises a routing tool driven by respective motors 14. Each motor 14 is supported on respective slides 15 arranged for sliding movement in a vertical direction along guide rails 16. The slides 15 are arranged to be selectively moved in opposite directions along the rails 16 by means of AC servo motor, such motor driving lead screws engaged with the 30 slides The shaping head 12 is supported on a frame 17 ooooo which is preferably an aluminium fabrication and which is supported for movement normal to the direction of movement of the shaping tools 13 and in a horizontal plane. The S" 35 frame 17 is also slidably supported on guides 17' with movement thereof along the guides also being controlled by :an AC servo motor driving lead screws to ensure accurate tpoi transverse positioning of the shaping head 12.

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1 op A clamping assembly 18 for selectively holding a product blank or block 19 is supported for movement on further guide rails 20 in a horizontal direction orthogonal to the directions of movement of the shaping head 12 and shaping tools 13. The clamping assembly 18 includes a pair of side members 21 which are supported on a frame 22 arranged for movement along the rails 20 and which extend in cantilever fashion therefrom to be interconnected at their free ends by a transverse support beam 23. A series of spaced apart elongated slots 24 are provided in the side members 21 to receive respective adjustable clamping screws the screws 25 being moveable inwardly or outwardly of the side members 21 and being moveable along the slots 24 to desired clamping positions. The end beam 23 is also provided with a central elongated slot 24 to accept a clamping screw 25 whilst an adjustable clamping beam 26 is arranged between the members 21 to be adjustable in a longitudinal direction relative thereto and clamped in a desired position therealong. The clamping beam 26 also includes a central elongated slot 24 and clamping screw Movement of the frame 22 along the guides 20 is also achieved by a servo motor and lead screw in a similar manner to movement of the shaping head and tools.

In use a block 19 to be shaped is positioned between the opposite clamping members 21 and the beam 26 moved to a position longitudinally of the members *o 21 so that the block 19 has its opposite ends positioned adjacent the beam 23 and beam 26. The adjustable clamping screws 25 may then be positioned in their slots 24 and 30 screwed in or out to engage the opposite sides and ends of block 19 so that the block 19 is supported about its o o periphery. Assuming the shape of the desired product has been determined on the computer using the CAD program, the shaping machine 10 is operated with movement of the shaping 35 tools 13 in a vertical direction, of the shaping head 12 in e a horizontal transverse direction and the clamping assembly 18 in a horizontal longitudinal direction being controlled bythe program driving the servo motors and the lead screws __bthe program driving the servo motors and the lead screws in accordance with the shape generated using the CAD program. This will result in a three dimensional reproduction of the visual image being formed in the product block 19.

In the case of the surf board the block 19 comprises a foam block and after shaping as above the block 19 forms a core or blank for a surfboard which is fibreglassed and finished as is normal. Alternatively finishing steps can be reduced by having the block 19 formed of a harder foam which has a relatively higher rigidity so the finishing steps may be reduced. In some instances self skinning materials may be used for the foam blank so that the need for fibreglass finishing is elimiuated.

Referring now to Figs. 3 and 4 there is illustrated an alternative clamping assembly 27 for holding the block 19 whilst shaping. As before the clamping assembly 27 includes a pair of side members 21 which support a front fixed beam 28 and a rear relocatable beam 29 which may be adjusted along the side members 21 and locked in a desired position. The beams 28 and 29 both include a fixed clamping jaw 30 and an adjustable clamping jaw 31 which is supported by clamping screws 32 movable along elongated slots 33 in the respective beams 28 and 29.

In this case the opposite ends of the block 19 are located between the beams 28 and 29 with the adjustable jaws 31 being moved downwardly to clamp the opposite ends of the block 19 in position.

The apparatus 10 is then operated as before to 30 form the block 19 into the required three dimensional form but leaving in this instance, after the shaping process in S"which the portions of the block 19 shown cross-hatched are removed, a relatively thin web or filament 34 connecting o& S" 9 the block 19 to the portions thereof clamped between the 35 clamping members 30 and 31. These portions can then be cut and trimmed to provide the required end product.

eeo In many instances it is desirable to collect the too* material cut from the block to reduce dust generation and o.

8 also for subsequent processing. For this purpose the dust extraction system 35 shown in Fig. 5 may be used, this system including an extraction unit 36 comprising a collection chamber 37 which communicates with an extraction motor 38 driving a suction fan, the latter being connected through an extraction duct assembly 39 to intakes adjacent the respective cutting tools 13. Filters 41 are provided in the chamber 37 so as to prevent dust escaping therefrom. Thus whilst the shaping tools 13 are operating the motor 38 is operated to drive the suction fan to draw in through the ducts 39 and the intakes 40 dust and other particles of displaced material for collection in the chamber The method and apparatus of the present invention permits a product to be initially designed to a particular configuration and shape using the conventional CAD program and rapidly manufactured in three dimensional form. Any variations can be made to the design using the CAD program and those variations can be simply transformed into variations in the end product using the shaping apparatus as described.

To minimise inertia, the movable components of the shaping apparatus are preferably fabricated of aluminium whilst the base of the apparatus is preferably formed of stress relieved steel. The lead screws for moving the parts of the apparatus are preferably hardened and precision ground ball screws with anti-backlash 'recirculating ball nuts whilst the lead screw motors are suitably rare earth AC servo motors. The linear ways or rails for guiding the moving components of the apparatus are suitably hardened and precision ground circular ways with recirculating ball carriage bearings.

It will be apparent that the apparatus of the invention may be of many different configurations from that 35 described and depicted in the drawings. For example, the clamping assembly side members 21 may be supported central on the frame 22 rather being supported in cantilever fashion. Other variations in design detail will be apparent to persons skilled in the art. The block for shaping into a surfboard core or blank suitably compr' es a foam (foam plastics material) of any suitable form.

Whilst the above has been given by way of illustrative embodiment of the invention, all such modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein defined in the appended claims.

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Claims

2. A method according to claim 1 wherein said shaping tool is arranged on one side of said foam block and wherein said shaping tool is moved longitudinally, transversely and towards and away from said foam block during said forming method. o 25 3. A method according to claim 1 or claim 2 wherein said shaping means includes a pair of said shaping tools arranged on opposite sides of said foam block and wherein said shaping tools are positioned and moved to remove material from on opposite sides of said block.
4. Apparatus for use in the method of claim 1, said apparatus including computer means for generating a visual image of said desired three dimensional form of said blank or core, shaping means including said at least one shaping co••Q: tool for removing material from said foam block, support means for supporting said foam block adjacent said shaping means, actuating means for moving said shaping tool relative to said block supporting means and a foam block held thereby, and control means for controlling said actuating means and thereby movement of said shaping tools relative to said block supporting means and foam block supported thereby, said control means controlling movement of said actuating means and shaping tools in accordance with said computer generated three dimensional desired form of said blank or core whereby said shaping tool is operative to remove material from said foam block to form said foam block into said required three dimensional form .0 of said blank or core. Sh ping apparatus according to Claim 4 wherein said shaping tools comprises first and second opposed said shaping tools and means are provided for supporting said shaping tools on opposite sides of said block supporting means for independent and relative movement towards and away from each other, and a foam block held by said block supporting means, along a first axis.
6. Shaping apparatus according to Claim 5 wherein said shaping tools are supported for movement in a shaping head and wherein means are provided for supporting said shaping head for movement along a second axis orthogonal to said first axis.
7. Shaping apparatus according to Claim 6 ,i.d including means for supporting said block supporting mt-ais for movement along a third axis orthogonal to said first and second axes. Apparatus according to Claim 6 or Claim 7 wherein said block supporting means is arranged for movement in a horizontal plane and wherein said first and second shaping tools of said shaping head are supported for 35 movement in a vertical plane.
9. Apparatus according to any one of Claims 6 to 8 wherein said shaping head is arranged for movement normal to the direction of movement of said support means in a horizontal plane. Apparatus according to Claim 6 wherein said supporting means for said block is fixed and said shaping head is arranged for movement along a third axis orthogonal to said first and second axes.
11. Apparatus according to any one of Claims 4 to wherein said block supporting means includes a pair of spaced apart support members between which said foam block is arranged to be supported, said block being adapted to be supported by a plurality of clamping fingers mounted on said support members and extending inwardly therefrom to engage said block in use.
12. Apparatus according to any one of Claims 4 to wherein said block supporting means is provided with clamps which are adapted to engage opposite sides and/or ends of said block.
13. Apparatus according to claim 11 or claim 12 wherein said support members are supported in cantilever fashion. see.
14. Apparatus according to any one of claims 4 to 13 0:06I6 wherein said shaping tools comprise motor driven routing tools. 30 15. Apparatus according to any one of claims 4 to 14 wherein said shaping head includes slide means for supporting said shaping tools for slidable movement.
16. A method of manufacturing a surfboard or other 35 like watercraft including the steps of forming a blank in accordance with the method of any one of claims 1 to 3 and providing said blank with a surface finish.
17. A method according to claim 16 wherein said blank is finished with glass reinforced plastics.
18. A surfboard or other like watercraft including a blank or core manufactured in accordance with the method of any one of claims 1 to 3.
19. A surfboard or other like watercraft including a blank or core manufactured using the apparatus of any one of Claims 4 to A method of shaping a blank or core for a surfboard or other like watercraft substantially as here.,nbefore described with reference to the accompanying drawings.
21. Apparatus for shaping a blank or core for a surfboard or other like watercraft substantially as hereinbefore described with reference to the accompanying drawings. DATED this tenth day of December 1993 :HARVEY ROBERTS PTY. LTD. 25 By Our Patent Attorney JOHN R.G. GARDNER C o *o ABSTRACT Apparatus (10) for shaping blanks (19) such as a blank of a surfboard including a shaping head (12) including oppositely arranged shaping tools (13) which are movable in a vertical direction towards and away from each other. The shaping head (12) is movable across the blank (19) in a horizontal plane and the blank (19) is supported by a clamping assembly (18) which is movable longitudinally in a horizontal plane. Movement of the tools, head and clamping assembly occurs under the control of a computer controlled positioning system which is responsive to a computer generated image of the proposed blank.