Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
  • B23D63/00—Dressing the tools of sawing machines or sawing devices for use in cutting any kind of material, e.g. in the manufacture of sawing tools
  • B23D63/18—Straightening damaged saw blades; Reconditioning the side surface of saw blades, e.g. by grinding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
  • B23D63/00—Dressing the tools of sawing machines or sawing devices for use in cutting any kind of material, e.g. in the manufacture of sawing tools
  • B23D63/008—Dressing the tools of sawing machines or sawing devices for use in cutting any kind of material, e.g. in the manufacture of sawing tools using computer control means

Definitions

• MULTIFUNCTIONAL TOOL MACHINE FOR CORRECTION OF PLANARITY ERRORS AND REDUCING TENSIONING IN DISK-SHAPED BLADES, AS WELL AS METHOD AND PROGRAM FOR CONTROLLING SUCH MACHINE
• This invention is generally directed to the field of machine tools and particularly relates to a multifunctional tool machine for correction of planarity errors and reducing tensioning in disk-shaped blades.
• the invention further relates to a method for controlling operation of the machine by a special computer program.
• Cutting or shearing of materials such as metals, glass, wood, stone materials in general, are known to be performed using toothed circular blades or similar disk- shaped tools, essentially formed of a disk-shaped metal plate having one or more sets of cutting edges along its periphery.
• the tool to be corrected has to be mounted to a support frame, which has suitable means for tool displacement and automatic control and error correction.
• control means are generally proximity sensors, which detect errors and use a transducer to transmit information thereof to one or more actuators for operating the corresponding tools.
• these tools are of the anvil and hammer type for straightening and of the roller or roller pair type for reduction of inner tensions by stretching or tensioning operations.
• the object of this invention is to overcome the above drawbacks, by providing a multifunctional machine tool for correction of planarity errors and reducing tensioning in a disk-shaped blade that is highly efficient and relatively cost- effective.
• a particular object is to provide a machine that allows to correct flatness defects of both faces of a blade while avoiding undue handling thereof for removal, overturning and further mounting to the machine, for enhanced reliability and safety.
• a further object is to provide a machine that performs both flatness defect correction and straightening operations on both faces of the blade in a fast repetitive manner.
• Another object of the invention is to provide a machine that allows to reduce dead times associated to tool replacement, while allowing simplified processing of the whole surface of the blade.
• Yet another important object of the present invention is to provide a machine in which control and defect correction operations are automatically managed by a computer and a program loaded therein, thereby enhancing versatility and allowing the machine to fit the various geometries of the tool to be corrected.
• the invention is characterized in that it comprises at least two pairs of pressure tools having respective anvils on opposite sides of the blade, wherein the pairs of pressure tools are mounted to a single support element to sequentially act on corresponding opposite faces of the blade.
• the machine may comprise at least one pair of tensioning rollers facing opposite faces of the blade and mounted to the support element with the pressure tools for tensioning state correction by rolling.
• the machine tool may perform both flatness defect correction and straightening operations on both faces of the blade in a fast and repetitive manner.
• the invention relates to a method for automatic correction of flatness and tensioning defects as defined in claim 24, comprising a step in which a disk-shaped blade to be corrected is locked to the bearing frame of the machine in a first position, a step in which the disk-shaped blade is displaced along the second axis to a second position, a first step of detection and analysis of blade flatness defects, a first step of actuation of at least one pair of pressure tools from opposite sides of the blade in a direction substantially parallel to a first axis for correcting flatness defects in the blade, the steps of detection and control and tool actuation being repeated to extend defect correction to the whole surface of the blade faces.
• the tool actuation step for correcting flatness defects is performed by at least two pairs of said pressure tools having respective anvils on opposite sides of the blade, the pairs being mounted to a single support element to sequentially operate on corresponding opposite faces of the blade, thereby avoiding removal, overturning and further mounting thereof.
• both faces of the blade may be corrected for flatness defects, while providing simpler and faster tool removal and reducing the associated dead times.
• the invention provides a computer program as defined in claim 33, which comprises a first operating subprogram for input and storage of physical parameters of a disk-shaped blade to be corrected, a second operating subprogram for positioning the blade in a first processing position, a third operating subprogram for collection and analysis of the shape and size characteristics detected by sensor means to generate an output signal, a fourth operating subprogram for comparison of the output signal generated by the third subprogram with a reference signal, to generate a signal for controlling the second and third actuator means, which is susceptible of correcting flatness and tensioning defects of the blade. Thanks to the above program, all correction and tensioning operations may be automatically handled, thereby enhancing versatility and allowing the machine to fit the various geometries of the tool to be corrected.
• FIG. 1 is a perspective view of a machine according to the invention
• FIG. 2 is a perspective view of a first detail of the machine of FIG. 1
• FIG. 3 is a perspective view of a second detail of FIG. 1 ;
• FIG. 4 is a perspective view of a third detail of FIG. 1 ;
• FIG. 5 is an enlarged view of a detail of FIG. 4;
• FIG. 6 is a first side view of the detail of FIG. 5;
• FIG. 7 is a second side view of the detail of FIG. 5, as taken along the median plane /-/;
• FIG. 8 shows a flowchart of a method for correcting flatness and tensioning defects according to the invention
• Fig. 9 shows a flowchart of a computer program for computerized control of the machine for carrying out the method of the invention.
• the machine tool of the invention which is generally designated by numeral 1 , may be particularly used to correct flatness and tensioning defects in tools having a disk-shaped blade L of the type having a central disk that defines an axis of rotation and a peripheral ring with a plurality of cutting edges thereon.
• the machine tool has a floor standing bearing frame 2, locking means 3 mounted to the frame 2 for removably locking the blade L to be corrected with respect to a first axis X, substantially coinciding with its axis of rotation, sensor means 4 for detecting flatness and tensioning defects in the blade L, and at least one pair of pressure tools 5', 5" for correction of such defects.
• Each pair of tools 5', 5" comprises an anvil 6 and a hammer 7 in facing relationship to each other to operate on opposite faces S 1 , S 2 of the blade L along a first direction di substantially parallel to the first axis X.
• the machine 1 comprises at least two pairs of pressure tools 5', 5" having respective anvils 6 on opposite sides of the blade L, the pairs 5', 5" being mounted to a single support element 8 to sequentially operate on corresponding opposite faces S-i, S 2 of the blade L.
• the disk-shaped blade L may be corrected for flatness defects without having to be removed from the machine 1 , overturned and mounted again to the bearing frame 2 in a reversed position.
• the machine 1 comprises at least one pair of tensioning rollers 9', 9" facing opposite faces S-i, S 2 of the blade L for tensioning state correction by rolling.
• the tensioning rollers 9', 8" are mounted to the support element 8 with the pairs of pressure tools 5', 5".
• each type of pairs of tools 5', 5", 9', 9" mounted to the support element 8, as well as their relative positions, may be susceptible to changes for adapting the functional and construction features of the machine 1 to operational requirements, without departure from the inventive concept as defined in the claims.
• the blade L to be corrected is placed on the machine 1 in a vertical plane ⁇ , wherefore its first axis of rotation X is horizontal.
• the blade L may be placed in a substantially horizontal or inclined plane, with the locking means 3 being configured in such a manner that the first axis X is always orthogonal to such plane ⁇ .
• the bearing frame 2 may be formed of a first bearing unit 10 for the locking means 3, and a second bearing and guiding unit 11 for the support element 8 for the pairs of tools 5', 5", 9', 9" and a gantry-type structure 12 for strengthening and connecting together the various parts of the machine 1.
• FIG. 3 shows the locking means 3 mounted to a carriage 13 that is movable along first guide means 14 integral with the bearing frame 2.
• the blade L may be driven parallel to itself along a second axis Y, substantially perpendicular to the first axis and horizontal in the illustrated configuration, by first actuator means 15 that operate on the carriage 13 by means of a feed screw 16 extending in a second direction d 2 substantially parallel to the second axis Y.
• Such screw 16 which is a worm actuated by a first motor 17, transmits its motion to the carriage 13 through a slider which is placed on the worm 16 under the carriage 13 and is not shown, thereby causing translation y of the carriage 13 and thence of the blade L.
• the first guide means 14 may be, for example, a pair of parallel and substantially horizontal guides with the carriage 13 being slideably mounted thereto.
• the locking means 3 may comprise a pair of retaining flanges 19 on respective faces S 1 , S 2 , which are rotatable about the first axis X and are mounted to the same actuator means 15.
• the first actuator means 15 comprise a motor-driven mandrel 20 for rotatably driving the flanges 19 about the first axis X, thereby allowing the blade L to perform full turns ⁇ about it.
• the shaft of the mandrel 20 may be connected to a second motor 21 either directly or, preferably, through a gearmotor 18 by means of a toothed belt transmission.
• the machine 1 can process the whole surface of the blade L by a simple sequence of translational y and rotational ⁇ movements.
• the support element 8 is movable with respect to the bearing frame 2 in a plane ⁇ ' substantially parallel to the first axis X.
• the plane ⁇ ' is substantially vertical.
• the support element 8 comprises a plate 22 mounted to second guide means 23, which is integral with the bearing frame 2 and substantially perpendicular to the first X and the second axis Y.
• second actuator means 24 are provided, i.e. a pair of hydraulic or oil jacks, having the same line of action ⁇ , substantially parallel to the first axis X and acting from opposite sides in opposite directions on both pressure tools 5', 5" and tensioning tools 9', 9" of each pair.
• each pair of pressure tools 5', 5" have each a substantially flat head 25', 25" secured to a respective elongate body 26', 26" which is movable relative to the plate 22 along the first direction di substantially parallel to the first axis X.
• the hammers 7 have at least one substantially cylindrical abutment member 27 at their respective heads 25", which is designed to hit the corresponding face S-i, S 2 of the blade L at the correction point, and to impart thereto the required corrective deformation F 1 transmitted by the jacks 24.
• the pair of tensioning rollers 9', 9" comprises, in turn, a motor driven roller 9' and an idle roller 9", both journalled to corresponding sliders 26', 26" which are movable in the first direction d-i with respect to the plate 22.
• the torque required for rotation of the rollers 9', 9" is provided by further motor means 18 connected to the drive roller 9', whereas the other roller 9" will be set into rotation by the friction generated upon contact with the surface of the corresponding face S 2 of the blade L.
• Third actuator means 29 will be further provided, having a pair of hydraulic or oil jacks operating on the plate 22 for selectively aligning one of the pairs of tools 5', 5", 9', 9" to the pair of hydraulic jacks 24, depending on the particular processing operation to be performed.
• the jacks 29 have the bottom end 30 integral with the bearing frame 2 and the opposite top end 31 operating on the plate 22.
• each pair of jacks 29 is composed of two coaxial and substantially vertical opposite pistons 29', 29".
• each jack 29 The relative position of the pistons 29', 29" of each jack 29 allows the plate 22 to be set at three different heights corresponding to the alignment of a specific pair of tools with the jacks 24.
• the pair of pressure tools 5" has the anvil 6 against the left face S 1 of the blade L and the hammer on the other face S 2 aligned with the jacks 24.
• the sensor means 4 include a transducer 32 connected to a tracer 33 which is designed to interact with either face of the blade L for detecting any flatness errors with respect to a median reference plane ⁇ " for the blade L, which substantially coincides with its lying plane ⁇ .
• the sensor means 4 include a pneumatic actuator 34 which is operatively connected to the tracer 33 to move it toward the blade L into contact with the face
• the tensioning state of the blade L is read by combining the action of the pair of actuators 35', 35", which are designed to exert respective equal compressive forces F 2 , F 3 on the blade L along respective third directions d 3 , d 3 > substantially parallel to each other and to the first axis L to cause bending of the blade L, which bending will be suitably detected by the transducer 32.
• the machine 1 may further include an electric, hydraulic and pneumatic control unit, not shown, which is connected to the first, second and third actuator means 15, 24, 29 for control and actuation thereof.
• a logic processor unit may be provided, also not shown, having inputs connected to the sensor means 4 and outputs connected to the control unit.
• a control program is installed in the logic unit, for bringing the pressure tools 5', 5" and the tensioning tools 9', 9" from an idle position in which they skim the surface of the blade L to an operating position in which they deform the blade in response to predetermined error signals generated within the logic unit.
• FIG. 8 shows a flowchart of a method for correcting flatness and tensioning defects in a disk-shaped blade L, using a multitool machine 1 as described hereinbefore.
• the method includes a step a) in which a disk-shaped blade L is locked on a bearing frame 2 in a first position, a step b) in which the blade L is translated y into a second position along the second axis Y, a first step c) of detection and analysis of flatness defects of opposite faces S 1 , S 2 of the blade L, a first step d) of actuation of the pair of pressure tools 5', 5" from opposite sides of the blade in a direction di substantially parallel to the first axis X, for correcting flatness defects.
• step e) The steps c) and d) are then repeated (step e)) for analyzing and correcting all flatness defects of the blade L.
• the method is characterized in that the first actuation step d) for correcting flatness defects is performed by at least two pairs of pressure tools 5', 5" having respective anvils 6 on opposite sides of the blade L, and mounted to a single support element 8 to sequentially operate on corresponding opposite faces S-i, S 2 of the blade L, thereby avoiding removal, overturning and further mounting thereof on the machine 1.
• the first actuation step d) may in turn include a step d') of sequential displacement of the blade L about the first axis X and along the second axis Y, alternated to a defect correcting step d") using one of the pairs of pressure tools 5', 5".
• the third actuator means 29 operate on the plate 22, depending on the face S 1 , S 2 of the blade L to be corrected, for aligning one of the pairs of pressure tools 5', 5" with the hydraulic jacks 24 which will provide the force F 1 required for correction processing.
• the blade L is rotated about the first axis X and translated along the second axis Y for correcting all flatness defects detected by the sensor means 4.
• the first detection and analysis step c) may be repeated to confirm that the blade L has been restored to proper flatness within the predetermined tolerance range.
• the flatness defect correction step d" may be repeated until the blade L is restored to flatness within the predetermined tolerance range.
• a first checking step c' may be executed for checking if the number of flatness defect correction attempts is greater than a predetermined maximum number of attempts, above which the blade L will be discarded.
• a second step f) of detection and analysis of the tensioning state of the blade L may be executed after the step c), using the pair of pneumatic actuators 35', 35" and the sensor means 4.
• Such tensioning state may be detected by having the actuators 35', 35" exert a compressive force F 2 , F 3 on the blade L along third directions d 3 , O 3 - substantially parallel to each other and to the first axis X and by detecting the deformation resulting therefrom, using the transducer 32.
• the tensioning state will be determined at the points of contact with the actuators 35', 35", depending on the type of bending deformation of the blade L.
• the blade L may be rotated by fixed angular steps, to allow full analysis thereof.
• the second tension detection and analysis step f) may be followed by a second step g) of actuation of the pair of rollers 9', 9" for correcting the tensioning state of the blade L.
• the second tensioning step g) may in turn include a step g') of displacement of the blade L along the second axis Y, to determine the radial position in which the pair of rollers 9', 9" has to be disposed, and a step g") of tensioning of an annular section of the blade L, obtained by rolling the pair of rollers 9', 9" on the plate 22.
• rollers 9', 9" are aligned with the jacks 24, by means of the hydraulic jacks 29, hence the drive roller 9' is actuated, whereas the idle roller 9" is driven into rotation by friction.
• the steps f) and g) may be repeated (step e 1 )).
• step f) may be executed again to confirm that the new tensioning state of the blade L is within the predetermined tolerance range.
• step g" may be repeated until the tensioning state is within the predetermined tolerance range.
• a second checking step f) may be executed for checking if the number of tensioning state correction attempts is greater than a predetermined maximum number of attempts, above which the blade L will be discarded.
• a last step h) may be provided for unlocking and removing the corrected blade L from the bearing frame 2.
• the step h) may be executed by translating the blade L along the second axis Y to an unloading position, possibly coincident with the loading position, so that it can be removed manually or by suitable unloading means, not shown.
• Fig. 9 shows a flowchart of a computer program 38 for controlling the machine 1 and for carrying out the method as disclosed above.
• the program comprises a first operating routine i which interacts with a data input unit M for input and storage of physical parameters D of a disk-shaped blade L to be corrected, a second operating routine ii for positioning the blade L in a first processing position, a third operating routine iii for collection and analysis of the shape and size characteristics P detected by sensor means 4 to generate at least one output signal 39', 39", a fourth operating subroutine iv for comparison of the output signal 39', 39" generated by the third subprogram iii with a reference signal, to generate at least one control signal 40, 41 to the first, second and third actuator means 15, 24, 29, which is susceptible of correcting flatness and tensioning defects of the blade L.
• the input parameters may be data concerning the size, construction and/or functional features of the blade L to be processed and flatness and tensioning tolerance parameters.
• the parameters D may be input using any magnetic storage means M or manually entered by an operator from a terminal.
• the third operating routine iii may include a first logical sequence of instructions v for analysis of flatness defects of the blade L and a second logical sequence of instructions vi for analysis of the tensioning state.
• the logical sequences v, vi may perform a comparison between the parameters P detected by the sensor means 4 and the parameters D acquired by the first subprogram i for generating, when appropriate, an output error signal 39', 39" and transmitting it to the fourth operating routine iv.
• This subprogram may include a third logical sequence of instructions vii, which interacts with the first logical sequence v, for generating a flatness defect correction control 40 to be transmitted to the first, second and third actuator means 15, 24, 29.
• the first and third actuator means 15, 29 receive angular and radial input parameters of the points to be corrected, related to predetermined reference planes.
• the second actuator means 24 receive an instruction regarding the strength of the force F 1 to be exerted on the pair of pressure tools 5', 5" prepared by the third actuator means 29.
• the fourth operating routine iv may include a fourth logical sequence of instructions viii, which interacts with the second logical sequence vi, for generating a tensioning state correction control 41 to be transmitted to the same first, second and third actuator means 15, 24, 29.
• the first and third actuator means 15, 29 receive radial input parameters of the annular sections of the blade where rolling is required, with respect to a predetermined reference plane, whereas the second actuator means 24 receive an instruction regarding the torque to be applied to the rollers 9', 9".
• the third operating subprogram iii may include a fifth logical sequence of instructions ix for final surface analysis of the blade L
• a fifth operating routine x may be provided for controlling removal of the blade L from the machine 1 , in response to a specific output control 42 of the third subprogram iii, e.g. generated by the fifth logical sequence ix, regardless of whether correction has had a positive result or the piece has to be discarded.
• the machine 1 of the invention fulfils the intended objects and particularly the object of correcting flatness defects by operating on both faces S-i, S 2 of a blade L, while avoiding removal, overturning and further mounting thereof.
• correction and tensioning operations may be performed in a sequential and automatic manner, while reducing the dead times associated to tool replacement.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Details Of Cutting Devices (AREA)
• Bending Of Plates, Rods, And Pipes (AREA)

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• 2005
  • 2005-12-02 IT IT000320A patent/ITVI20050320A1/it unknown
• 2006
  • 2006-12-01 EP EP06832049A patent/EP1960144A2/de not_active Withdrawn
  • 2006-12-01 WO PCT/IB2006/054557 patent/WO2007063527A2/en not_active Ceased

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