US3918210A

US3918210A - Apparatus for milling faces of masonry blocks

Info

Publication number: US3918210A
Application number: US477633A
Authority: US
Inventors: Takeshi Mori
Original assignee: Christensen Diamond Products Co
Current assignee: Norton Christensen Inc
Priority date: 1972-09-05
Filing date: 1974-06-10
Publication date: 1975-11-11
Anticipated expiration: 1992-11-11

Abstract

Apparatus for supporting masonry blocks on a bed and gripping them between a row of movable powered members and a row of opposed support or thrust members, to continuously feed the blocks into a cutter station and between two parallel diamond set milling cutters that simultaneously mill opposed faces of each block to the desired gauge and parallelism, the finished blocks discharging from the cutter station.

Description

United States Patent [191 Mori [451 Nov. 11,1975

1 1 APPARATUS FOR MILLING FACES OF MASONRY BLOCKS [75] Inventor: Takeshi Mori, Salt Lake City, Utah [73] Assignee: Christensen Diamond Products Company, Salt Lake City, Utah 22 Filed: June 10,1974

21 Appl. No.: 477,633

Related US. Application Data [63] Continuation of Ser. No. 286,035, Sept. 5, 1972,

abandoned.

[52] US. Cl. 51/80 A; 125/3 [51] Int. C1. B2413 9/06 [58] Field of Search 51/80 R, 80 A, 81 R, 87 R, 51/76; 125/3 [56] References Cited UNITED STATES PATENTS Funk 125/26 2,671,992 3/1954 Reaser 51/80 3,136,094 6/1964 Reaser 51/76 3,150,469 9/1964 Berenbak... 51/80 3,166,874 l/l965 Bottcher 51/87 FOREIGN PATENTS OR APPLICATIONS 1,801,337 9/1970 Germany 125/3 Primtu v E.\'aminerI-Iaro1d D. Whitehead Attorney, Agent, or FirmBernard Kriegel ABSTRACT Apparatus for supporting masonry blocks on a bed and gripping them between a row of movable powered members and a row of opposed support or thrust members, to continuously feed the blocks into a cutter station and between two parallel diamond set milling cutters that simultaneously mill opposed faces of each block to the desired gauge and parallelism, the finished blocks discharging from the cutter station.

30 Claims, 24 Drawing Figures Sheet 1 of 12 US. Patent Nov. 11, 1975 US. Patent N0v.'1 1, 1975 Sheet20f12 3,918,210

U.S. Patent Nov. 11, 1975 Sheet30f12 3,918,210

0 Ill \QQ r- K m R Q wk mw l I wk U.S. Patant Nov. 11, 1975 Sheet4 of 12 3,918,210

US. Patent Nov. 11, 1975 Sheet5 of 12 3,918,210

E an].

U.S. Patent Nov. 11, 1975 Sheet6 of 12 3,918,210

US. Patent N0v.11, 1975 Sheet7of12 3,918,210

US. Patent Nov. 11,1975 Sheet8of 12 3,918,210

US. Patent Nov. 11, 1975 Sheet 9 of 12 US. Patent Nov. 11, 1975 Sheet 10 of 12 3,918,210

US. Patent Nov. 11, 1975 Sheet 11 of 12 3,918,210

US. Patent Nov. 11, 1975 Sheet 12 oflZ 3,918,210

' ished in several different manners. One mode included the positioning of each block on a bed and pulling the block with a drag chain across a cutting unit to provide the finished block surface, the chain being returned to its initial position to pull the next block across the cutting unit. Another method of finishing a block face is to clamp the block to a table that is shifted to move the block across the cutting unit, the table being returned to its initial position to receive the next block. The prior apparatus is intermittent in its operation and has a relatively low production rate. In addition, only a single block face may be cut at a time, requiring a plurality of sequential operations on the block in the event its opposed mortar receiving faces are to be finished to their required parallelism and with the block having the required height. In fact, the production of opposed parallel surfaces on masonry blocks and their finishing to the desired height has been difficult to accomplish, particularly in an economical manner. a

By virtue of the present invention, an apparatus is provided having a continuously moving mechanism for feeding blocks toward and between opposed cutters for simultaneously finishing opposed faces of each block to a desired shape and surface finish, the blocks also being produced to the desired height or other dimension, and with the opposed faces parallel to each other. As a result, the apparatus has a high production rate, being capable of producing blocks passing through the apparatus of consistent dimensions and shape, and with a high degree of accuracy, over an extended period. By properly selecting the cutters used in the apparatus, the opposed sides of the blocks can be faced or surfaced and corners or other parts of the blocks cut simultaneously, thereby avoiding separate operations and perhaps separate equipment. The apparatus is readily adjustable to accommodate blocks of different widths and of different heights.

In general, the masonry or other blocks are placed on a bed of supporting rollers at the rear of the apparatus, the blocks being pushed forwardly until their opposed sides are gripped between a row of powered pads, or the like, at one side and a row of supporting rollers at 'the other side. The powered pads move the blocks positively along the bed toward a cutter station where an upper roller, or the like, is held in contact with the upper face of each block, thereby holding it firmly against the bottom supporting rollers, such block then being held on all four sides (i.e., top, bottom and opposed sides) as it moves through the cutter station, where upper and lower rotating cutters simultaneously face the top and bottom of each block, the finished block discharging forwardly from the cutter station. As noted above, appropriately shaped cutters are mounted in the apparatus. The opposed faces of each block can be milled to the desired gauge simultaneously with the chamfering or bevelling of the longitudinal corners of each block. The spacing between the row of powered pads and the row of supporting rollers can be varied to accommodate different widths of blocks. Moreover,

the distance between the upper and lower cutters can be varied to accommodate blocks of different heights. The cutters are also adjustable with respect to each other to insure the production of parallel top and bottom surfaces on each block.

This invention possesses many other advantages, and has other purposes which may be made more clearly apparent from a consideration of a form in which it may be embodied. This form is shown in the drawings accompanying and forming part of the present specification. It will now be described in detail, for the purpose of illustrating the general principles of the invention; but it is to be understood that such detailed description is not to be taken in a limiting sense.

Referring to the drawings:

FIG. 1 is a side elevational view of an apparatus embodying the invention;

FIG. 2 is an isometric view of a finished masonry or concrete block;

FIG. 3 is a vertical view taken along the line 3-3 on FIG. 1;

FIG. 4 is a horizontal view taken along the line 4-4 on FIG. 1;

FIGS. 5a and 5b together constitute a vertical view of the apparatus taken along the line 5-5 on FIG. 4, FIG. 5b constituting a forward horizontal extension of the apparatus illustrated in FIG. 5a;

FIG. 6 is an enlarged fragmentary view illustrating the driving connection between one of the drive sprockets for moving a row of driving pads along the apparatus to feed the blocks in a forward direction;

FIG. 7 is a vertical view, on an enlarged scale, taken along the line 7-7 on FIG. 4;

FIG. 8 is a vertical end view taken along the line 8-8 on FIG. 7;

FIG. 9 is a section taken along the line 9-9 on FIG.

FIG. 10 is a section taken along the line 10-10 on FIG. 8;

FIG. 11 is a section taken along the line 11-11 on FIG. 8;

FIG. 12 is a section taken along the line 12-12 on FIG. 9;

FIG. 13 is a section taken along the line 13-13 on FIG. 9;

FIG. 14 is a view similar to FIG. 13 disclosing the adjustment of parts to a different position;

FIG. 15 is a view similar to FIG. 13 disclosing the parts having been adjusted to still another position;

FIG. 16 is a vertical view taken along the line 16-16 on FIG. 7;

FIG. 17 is a view of a portion of the apparatus illustrated in FIG. 7, and disclosing a row of blocks passing between the top and bottom cutters and being milled thereby;

FIG. 18 is an enlarged fragmentary vertical section illustrating the bottom cutters milling upon the lower portion of the block;

FIG. 19 is a fragmentary section taken along the line 19-19 on FIG. 18;

FIG. 20 is a vertical transverse section taken along the line 20-20 on FIG. 17;

FIG. 21 is a horizontal view of the exit slide portion of the apparatus taken along the line 21-21 on FIG.

FIG. 22 is a cross-section, with sides shown in side elevation, taken along the line 2222 on FIG. 21; and

FIG. 23 is a vertical sectional view, with parts shown in side elevation, taken along the line 2323 on FIG. 7.

In the apparatus illustrated in the drawings, a row of masonry blocks B, such as concrete blocks, are mounted on a lower bed and clamped between a row of vertically arranged side support rollers 11 engaging the side faces 12 of the row of blocks on one side and a row of driving members 13 engageable against the other side 14 of the row of blocks, the driving member and side support rollers gripping the opposed faces 12, 14 of the blocks to propel them from the rear of the apparatus forwardly toward a cutter station C at which the top and bottom faces 15, 16 of the blocks are milled simultaneously, the blocks then being shifted forwardly onto an exit slide S and then onto a forward set of horizontal rollers 19b (FIG. 5b) to a location where they can be withdrawn from the apparatus.

The apparatus includes a framework 18 having a plurality of adjacent bottom rollers 19 rotatable about axes normal to the direction of travel of a concrete block. These bottom supporting rollers extend from the rear of the machine to the cutter station C. They are each rotatably mounted on a shaft 20 (FIG. 23) through suitable intervening bearings (not shown), the shaft being supported on vertical standards 21 suitably affixed to a bottom horizontal subframe 22, which is, in turn, vertically adjustable with respect to the horizontal bottom portion 23 of the main frame by means of adjusting screws 24. By suitable adjustment of the screws, the row of bottom supporting rollers 19 can be accurately positioned to support the blocks B horizontally for movement through the apparatus to the cutter station C.

The blocks are driven in a forward direction along the horizontal support rollers 19 by a longitudinally extending drive mechanism 25, including a plurality of closely spaced vertical drive pads 13 that extend laterally from an endless chain 27 passing over and meshing with a sprocket 28 at the rear portion of the frame 18, and a forward sprocket 29 disposed forwardly of the discharge end of the apparatus forwardly of the exit slide device S (FIG. 4). The plurality of vertically arranged pads 13 extend laterally inwardly of the apparatus, being secured to the links of the chain, the links and pads being supported by a stationary horizontal support plate 30 extending longitudinally along the frame and suitably secured thereto, and with rollers 31 of the links bearing against the vertical inner surface of a guide rail 32 suitably secured to the machine frame. The chain 27 is driven at the appropriate speed by rotating the forward sprocket 29 about its vertical axis through a suitable drive mechanism, which may include an electric motor 35 operating through a suitable variable speed gear reducer 36, to drive a sprocket 37 over which passes a chain 38 that transmits its motion to another sprocket 39 secured to a countershaft 40. Fixed to the shaft 40 is yet another sprocket 41 driving a chain 42 passing over a driven sprocket 43 secured to a shaft 44 to which the forward sprocket 29 is secured (FIG. 4), which moves the chain 27 and its pressure pads 13 from the rear to the front of the apparatus, the chain being endless and passing from the forward sprocket back around the rearward sprocket.

The sides 14 of the blocks are pressed against the drive pads 13 by a row of vertical side support rollers 11 mounted adjacent one another and adapted to bear against the opposite sides 12 of the blocks. Through suitable bearings (not shown), each of the side support rollers 11 is mounted upon a vertical shaft 50, which, in turn, is affixed to upper and lower parallel elongate mounting plates 51 that straddle an intervening support plate 52 suitably affixed to the main frame 18 of the machine. The opposed mounting plates have cut-out portions 53 at spaced intervals along their length to straddle parts of the support frame 18 and to permit lateral adjustment of the mounting plates with respect to the support plate. Horizontal adjusting screws 54 (FIGS. 3, 4) at the forward and rearward ends of the mounting plates 51 are rotatably mounted in the frame, each of these adjusting screws being threadedly received within a suitable nut 55 extending between and secured to the upper and lower mounting plates 51. By turning the adjusting screws in the proper direction, the mounting plates and the row of vertical side support rollers 11 rotatably secured thereto can be moved toward and from the row of drive pads 13, in order to accommodate the width of the particular blocks that are to be moved along the horizontal bed of rollers 19. As is evident from FIG. 3, the rollers 19 are substantially longer than the width of the blocks, enabling blocks of varying widths to be accommodated on the apparatus. The screws 54 are adjusted to provide the proper horizontal spacing between the side support rollers l1 and the drive pads 13 and to clamp the blocks B therebetween as they are being moved by the drive pads forwardly along the bed of bottom rollers 19 and through the cutting station C. Preferably, the block engaging surfaces of the drive pads 13 have a soft elastomer surface, such as provided by polyurethane; whereas, the rim portions of the side support rollers 11 are made of a hard elastomer material, such as polyurethane. Additionally, the rims of the bottom rollers 19 are made of a soft elastomer material, such as polyurethane, to accomdate irregularities in the bottom face of each block. As a result, the elastomer surfaces yield slightly to insure firm engagement of the block by the bottom rollers and firm gripping of the blocks between the side support rollers 11 and the drive pads 13, thereby insuring their positive feeding along the bottom roller bed toward and through the cutter station C.

It is to be noted (FIG. 4) that one or two of the rear side support rollers 11a are spaced laterally from the row of drive pads 13, when their associated chain link rollers 31 engage the guide rail 32, a distance greater than the width of a block, leaving an entry gap into which the blocks can pass prior to engaging the side support rollers 11 forwardly of the retracted rollers 11a, where they will then become clamped between the side support rollers and the pads.

When the blocks B reach the cutter station C, they pass between an upper rotatable milling cutter and a lower rotatable milling cutter 61. As disclosed most clearly in FIG. 20, the lower cutter 61 is affixed to a suitable arbor or horizontal shaft 62 extending transversely of the apparatus and suitably supported through bearings 63 in bearing supports 64 affixed to the frame 18 of the apparatus. The perimeter of the rotatable cylindrical milling cutter 61 will extend slightly above the bottom face 16 of the blocks when resting on the bottom supporting rollers 19, so as to remove material from the bottom of the block and produce a finished bottom face thereon. As specifically disclosed, the cutter may have bevelled outer portions'65 for producing a corresponding bevel 66 along the longitudinal lower edges of each block.

The upper rotatable milling cutter is suitably secured to an arbor 67 rotatably mounted through suitable bearings (not shown) on bearing supports 68 and having a shaft portion extending therefrom. This cutter 60 is rotatable about a horizontal axis 69 which is forward of a vertical plane passing through the axis 70 of the lower cutter 61. Its perimeter will extend slightly below the upper surface 15 of each block to be finished, so as to remove a required amount of material therefrom, and thereby provide a finished top face 16 on each block. If desired, and as illustrated in the drawings, the upper cutter may also have side bevelled portions 65 adapted to cut away the upper longitudinal corners of the block and provide companion longitudinal bevels 66 therealong.

The upper rotatable cutter 60 is suitably driven from a top arbor motor 72 mounted on the frame (FIG. 1), the motor shaft being secured to a drive pulley 73 having belts 74 passing therearound which also pass around pulleys 75 affixed to the upper arbor shaft 67. Similarly, a bottom arbor motor 76 is suitably secured to the frame 18, having drive pulleys 77 around which belts 78 pass that also pass around driven pulleys 79 secured to the lower arbor shaft 62. The upper and

lower cutters

60, 61 are rotated at the desired speed to cut the top and

bottom portions

15, 16 of the blocks as they pass forwardly through the cutter station C. The cutters themselves and the cuttings are continuously removed by suitable flushing liquid passing through upper and

lower manifolds

80, 81 extending across and parallel to the cutters and having nozzles 82 therein for discharging the liquid against the peripheries of the cutters, as illustrated in FIGS. 17 and 18. Suitable hoses 83 conduct the liquid to the

manifolds

80, 81, the water and cuttings dropping into suitable trays 84 affixed to the frame 18 and underlying the bed 10, 'cutter station C, and exit slide S.

The desired vertical spacing between the upper and

lower cutters

60, 61 is achieved through the vertical adjustability of the upper cutter elative to the lower cutter. As disclosed in FIGS. 7, 8/and 17, the upper cutter and its arbor are mounted in a subframe 85 that includes vertical standards 86 secured to a transverse head 87 having a threaded nut 88 mounted centrally therein. A feed screw shaft 89 extends vertically through the nut, with the upper end 90 of the shaft being rotatable in a crosshead 91 suitably affixed to the 'frame of the machine. Secured to the upper feed-screw shaft is a worm wheel 92 resting upon a roller thrust bearing 93, which, in turn, rests upon the frame crosshead 91 to support the subframe 85 and the cutter 60 in the vertical position to which it has been adjusted. Such adjustment is effected by. rotating a crank 94 (FIG. 16) secured to a shaft 95 rotatably mounted in suitable bearing supports 96 of the framework, this shaft being affixed to a worm 97 meshingwith the .worm wheel 92. By suitably rotating the crank 94 and the worm 97 in the appropriate direction, the feed screw 89 is rotated to correspondingly elevate or lower the subframe 84 and the upper cutter device rotatably mounted thereon. After the desired adjustment has been secured, which will provide the desired vertical spacing between the lower cutter 61 and the upper cutter 60, clamp screws 98 secured to the framework 18 and extending through longitudinal slots 99 in the subframe standards 86 can be tightened to clamp the subframe 85 in its vertical position with respect to the main frame 18 of the machine.

Carried by the subframe 85 and on opposite sides of the upper milling cutter 60 is an elongate rearward holding roller 100 and an elongate forward holding roller 101, both of which are adapted to bear against the top 15 of a block B as it is passing through the cutter station C and between the upper and lower

rotatable milling cutters

60, 61. The rearward roller 100 is rotatably carried by arms 102 pivotally supported on the subframe 85, there being a row of appropriate helical compression springs 103 bearing against the arms and against a member 104 fixed to the frame 85 to urge the roller 100 downwardly and firmly against the upper surface 15 of the block. An arm extension 105 is provided that carries an adjustable stop 106 bearing against the frame 85 to limit the extent of downward movement of the arms and roller 100 in the absence of a block B therebeneath. A similar arrangement is provided for the forward roller 101, the spring mechanism 103 urging its arms and the forward roller downwardly, shifting the latter to a slightly lower position that the rearward roller 100 because of the fact that the upper surface 15 of the block has been milled away by the cutter 60 to some extent.

The rearward roller 100 and the foward roller 101 hold the blocks B downwardly against the bed rollers 19, clamping the blocks therebetween. Such clamping action, coupled with the clamping of the blocks between the drive pads 13 and side support rollers 11, results in each block being held firmly on all four of its sides as it passes between the two parallel

rotatable milling cutters

60, 61. This results in both the upper and lower faces 15, 16 of each block being milled simultaneously to the desired gauge and flatness. lf appropriate cutters are provided, as illustrated in the drawings, the longitudinal comers 66 of the blocks may also be chamfered at the same time.

The top cutter 60 is adjustable to place its axis 69 in parallel relation to the axis 70 of the bottom cutter. As disclosed, the top cutter supporting frame has side members at opposite sides of the top cutter, these side members being mounted at one end of the side members on pivot pins 121 extending within suitable bores 122 in the outer frame portions 86 for the top cutter. Near the opposite end of the side members 120, rotatable eccentrics 123 are mounted in frame slots 124, a shaft 125 extending from each eccentric and rotatable in a bearing 126 in the outer frame member 86. The outer end 127 of each eccentric shaft may be formed to receive a suitable adjusting tool for the purpose of turning each eccentric 123 within its outer frame member 86 and its slot 124. Clamp screws 128 extend through vertical slots 129 in the sides of the outer frame members 86 below the eccentrics 123, passing through the inner frame members 120. Tightening of these screws will secure the

frame members

120, 86 together; whereas, their loosening will permit rotation of the eccentrics 123 for the purpose of pivoting the inner frame structure 120 on its pivot pins 121, thereby tilting the axis 69 of the upper cutter from a non-parallel relation to the axis 70 of rotation of the lower arbor and cutter td a parallel relationship; (-Tl'zimp screws 130 also extend through the outer side members 86 above the axis of the pivot pins 121, passing through openings 131 in the inner and

outer side members

86, 120 and being threadedly secured to the innermost portion of the supporting frame for the upper cutter. Tightening of these clamp screws will serve to secure the several frame portions to one another after the desired adjustment of the upper arbor axis with respect to the lower arbor axis has been effected. FIGS. 13, 14 and 15 illustrate different rotary positions of the eccentrics to disclose the manner of upwardly tilting one side of the frames about the pivot pins 121, or downward movement or tilting of the frames about the axis of the pivot pins.

The blocks B discharge or exit from the cutter station C between the upper and

lower cutters

60, 61 onto the exit slide assembly S, the upper surface of which is horizontal, lying in the same plane as the uppermost portion of the cylindrical periphery of the lower cutter 61. This exit slide assembly includes a plurality of laterally spaced, longitudinal rails 151 disposed in longitudinal grooves 152 in a plate 153 that is longitudinally adjustable with respect to a laterally adjustable, horizontal plate 154, this last-mentioned plate resting upon a longitudinally and vertically shiftable base 155. The rails are retained within their grooves 152 and secured to the longitudinally adjustable plate 153 by cap screws 156; whereas, the longitudinally adjustable plate 153 is secured to the laterally adjustable plate 154 by cap screws 157 extending through the longitudinal slots 158 in the plate 153. The laterally adjustable plate 154 is shiftable transversely of the base and is releasably clamped in adjusted position by cap screws 159 extending through elongate transverse slots 160 in the longitudinally adjustable base. Tightening of the screws, when the desired positions of adjustment have been achieved, will secure the parts together in the desired relative positions.

The rails 151, longitudinally adjustable plate 153, and laterally shiftable plate 154, and base 155 are movable vertically as a unit, so as to position the upper surfaces 150 of the rails in a horizontal plane tangent to the periphery of the bottom cutter 61. To secure such adjustment, the longitudinally shiftable base 155 is attached to laterally spaced slides by screws 166, or the like, these slides having lower surfaces 167 inclined in an upward and rearward direction toward the location of the bottom cutter, such lower surface of each slide bearing upon a companion upper inclined surface 168 of a fixed base 169 of the main frame 18 of the machine. The slides 165 have their upper portions received within grooves 170 in the longitudinally shiftable base 155, their lateral motion being prevented by embracing side plates 171 attached by screws 172, or the like, to the inclined fixed member 169. As inclined adjusting screw 173 is rotatably mounted in a stationary boss 174 affixed to the main frame 18, this screw being threadedly received in a bore 175 in the forward end of one of the slide 165. A clamp screw 176 extends through a longitudinal slot 177 in the slide 165 and is threaded into the inclined fixed member 169. Loosening of the clamp screw 176 permits the adjusting screw 173 to be appropriately turned, which will move the entire exit slide assembly along the inclined plane 168 both longitudinally and vertically relative to the bottom cutter 61. When appropriately vertically adjusted, so that the top surfaces 150 of the rails 151 lie in the desired horizontal plane, the clamp screw 176 is tightened. The plate 153 can then be shifted toward the bottom cutter 61, so that the rear ends of the rails are closely adjacent to the periphery of the cutter without touching it, as permitted by the rearward bottom inclined surfaces 180 of the rails, whereupon the clamp screws 157 are tightened to secure the longitudinal adjusting plate to the lateral adjusting plate 154. If lateral adjustment is required, the clamp screws 159 are loosened to permit such action to take place, whereupon they are retightened.

As described below, the rails 151 can be positioned variously across the longitudinal adjusting plate 153, and the longitudinal adjusting plate 153 placed in different lateral positions on the lateral adjusting plate 154, to accommodate the blocks B of different widths. Thus, the rails 151 are receivable within intermediate grooves 152a and also within end grooves 152b, the rails being disposed in appropriate grooves and secured therein by the fastening screws 156, depending upon the width of block B passing through the apparatus. Moreover, the longitudinal adjustable plate 153 can be shifted laterally of the laterally adjustable plate by unthreading the clamp screws 157 from the laterally adjustable plate and shifting the longitudinally adjustable plate laterally until the screws can be placed in another set of spaced threaded holes in the laterally adjustable plate 154. As specifically disclosed, the longitudinally adjustable plate 153 can occupy two different lateral positions relative to the laterally adjustable plate, as determined by a locating key 191 disposed in a groove 192 in the lower side of the longitudinally adjustable plate and disposed selectively in one of the two grooves 193 disposed downwardly from the top surface of the laterally adjustable plate. The key 191 is retained in position on the longitudinally adjustable plate by one of the screws 156 that secures an intermediate rail 151 to the top plate 153, the spacing between the lower plate grooves 193 corresponding to the spacing be tween the adjacent threaded bores 190 in the plate 154, in which the clamp screws 157 are to be selectively disposed. With the arrangement described, the rails 151 can be variously spaced from each other, the distance between the outermost rails being variable. In addition, the location of the rails can be changed by the lateral position of a plate 153 with respect to the plate 154.

It is again to be noted that the top cutter 60 has its axis 69 lying in a vertical plane disposed forwardly of the vertical plane passing through the axis 70 of the lower cutter 61. Accordingly, the lower surface 16 of the block B will move onto the rails 151 at the com mencement of the cutting operation of the top cutter 60 on the top surface 15 of each block, and as the block continues to move in the forward direction, the forward spring-loaded member 101 will engage the upper finished surface 15 and retain the block firmly against the rails 151, the block still being moved forwardly by the drive pads 13 and with its

sides

14, 12 still being firmly engaged between the drive pads and the side support rollers 11. As disclosed most clearly in clearly in FIGS. 5a, 5b, the finished blocks B will move from the exit rails 151 onto horizontal support rollers 19a extending in a forward direction to an appropriate location at which the blocks can be unloaded from the apparatus.

The

cutters

60, 61 are preferably of the diamond-set type, and, specifically, may be of the type illustrated and described in US. Pat. No. 3,196,585, in which all of its diamond cutting elements collectively can operate upon the full surface area of the block B being faced; that is, the top cutter 60 will perform an appropriate milling action against the upper surface 15 of the block and the bottom cutter 61 against the lower surface 16 of the block.

In the use of the device, the blocks B are placed on the supporting rollers 19 at the rear of the apparatus and are pushed forwardly until they are gripped between the row of powered pads 13 and opposed support rollers 15, which move the blocks toward the cutter station C where the top face 15 of 'each block is contac'ted by the rearward spring-loaded roller 100 which holds the block firmly in contact with the bottom supporting rollers 19. As each block moves between the upper and

lower cutters

60, 61, it is held on all four sides, both faces l5, 16 being milled simultaneously to the desired gauge. If the cutters are the same as the shape specifically illustrated, the longitudinal corners 66 of each block as chamfered or bevelled at the same time. The finished block is discharged onto the exit slide rails 151, where the forward spring-pressed roller 101 contacts the upper finished face 15 of the block and holds it firmly against the rails, the driving pads 13 and the opposed support rollers 11 continuing to bear against the

sides

14, 12 of the block, insuring its forward movement off the slides 151 onto the discharge or exit horizontally disposed rollers 19a.

The blocks are continuously fed forwardly with the opposed faces 15, 16 of each block being simultaneously milled or shaped. All that is necessary to do is to place the blocks B on the rollers 19 at the rear of the machine and remove them from the discharge rollers 19b. It is unnecessary to use sliding or reciprocating tables or drag chains, such apparatus being intermittent in operation. In the present case, the blocks are fed continuously and make a single pass through the apparatus to cut the opposed surfaces on each block. The production rate is greatly increased, as compared with prior apparatus, the surface finish on each block being within the required specifications. The dimensions of each block are consistent, particularly through use of the diamond-set cutters of the type disclosed in US. Pat. No. 3,196,585.

The apparatus is readily adjustable to accommodate blocks of different heights and widths by adjusting the position of the side support rollers 11 with respect to the row of drive pads 13, and by suitably adjusting the vertical position of the top cutter 60 with respect to the bottom cutter 61. Moreover, the top cutter can be placed in a precise parallel relation with respect to the bottom cutter, to insure the uniform height of each finished block. Diamond-set cutters have a long life and are capable of producing a great number of blocks to the desired surface smoothness and vertical height without wear, the resulting product being well within the desired tolerances.

Because of the accuracy with which the apparatus is capable of finishing the top and bottom faces l5, 16 of each block, concrete masonry units can be rapidly and accurately laid in the usual fashion and readily adhered to one another. This ,is due to the accuracy with which the top and bottom faces are milled, and the further fact that they are parallel to each other, the height of the block and theflatness of the faces being consistently precise. In building a wall, for example, if the starting or foundation surface is not horizontal, it can be levelled initially in a bed of conventional cement mortar. Of course, if it is initially in a horizontal and flat condition, this step becomes unnecessary. The concrete blocks, which have been precisely dimensioned through use of the apparatus described, can be laid in rows with no further levelling, a thin bead of an adhesive, such as an adhesive mortar, forming an appropriate and tenacious bond between adjacent coarses of the concrete blocks. The thin adhesive, which can actually be constituted by nothing more than a relatively thin film of an epoxy resin, will insure the production of a strong monolithic wall structure. If it is desired to produce shadow lines or to simulate a mortar joint, the top and bottom cutters employed can produce the bevels 66 along the horizontal edges of the blocks.

I claim:

1. In apparatus for facing blocks: a supporting bed to receive the blocks with one face of the blocks resting on said supporting bed; a cutter station at the forward portion of said bed and including one or more cutters for cutting one or more faces of each block; an elongate endless drive member having adjacent drive pads thereon for engaging one side of each block other than said one face to transmit the drive force of said drive member and pads to said one side and feed the blocks forwardly along the bed and across said one or more cutters, whereby a cutting action is performed on one or more faces of each block; a stationary uninterrupted elongate guide rail disposed parallel to the direction of feed of the blocks and engaged by said drive member and along which said drive member is movable to support said drive member and pads for movement in a fixed plane while said pads are engaged with said one side of each block; support means for engaging the side of each block opposite said one side to maintain the blocks in driving engagement with said pads as said drive member and pads feed the blocks forwardly along the bed and across said one or more cutters; and means supporting said support means in another fixed plane for engagement with the opposite side of each block, whereby each block is clamped between said pads and support means.

2. In apparatus as defined in claim 1; and exit means forwardly of said cutter station for supporting the blocks during their passage'through the cutter station and with said pads and support means continuing their engagement with the sides of the blocks.

3. In apparatus as defined in claim 1; wherein said one or more cutters comprise opposed cutters substantially simultaneously engaging opposite faces of each block which are not engaged by said pads and support means to perform a cutting action on such opposite faces.

4. In apparatus as defined in claim 1; wherein said supporting bed, drive member and pads and support means are each elongate to simultaneously engage a plurality of blocks and feed such blocks successively toward andv through said cutter station.

5. In apparatus as defined in claim 1; wherein said one or more cutters comprise opposed cutters substantially simultaneously engaging opposite faces of each block which are not engaged by said drive means and support means to perform a cutting action on such opposite faces; said supporting bed, drive member and pads and support means each being elongate to simultaneously engage a plurality of blocks and feed such blocks successively toward and through said cutter station.

6. In apparatus as defined in claim I; wherein said one or more cutters comprise opposed cutters substantially simultaneously engaging opposite faces of each block which are not engaged by said pads and support means to perform a cutting action on such opposite faces; said supporting bed, drive member and pads and support means each being elongate to simultaneously engage a plurality of blocks and feed such blocks successively toward and through said cutter station; and exit means forwardly of said cutter station and separate from said supporting bed for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the sides of the blocks.

7. In apparatus as defined in claim 1; said pads and support means having elastomer surfaces engaging the sides of each block to grip each block between said drive means and support means.

8. In apparatus as defined in claim 1; wherein said one or more cutters comprise opposed cutters substantially simultaneously engaging opposite faces of each block which are not engaged by said pads and support means to perform a cutting action on such opposite faces; said supporting bed, drive member and pads and support means each being elongate to simultaneously engage a plurality of blocks and feed such blocks successively toward and through said cutter station; said pads and support means having elastomer surfaces engaging the sides of each block to grip each block between said pads and support means; said supporting bed having an elastomer surface engaging and gripping each block.

9. In apparatus as defined in claim 1; wherein said one or more cutters comprise opposed cutters substantially simultaneously engaging opposite faces of each block which are not engaged by said pads and support means to perform-a cutting action on such opposite faces; said supporting bed, drive member and pads and support means each being elongate to simultaneously engage a plurality of blocks and feed such blocks successively toward and through said cutter station; said pads and support means having elastomer surfaces engaging the sides of each block to grip each block between said pads and support means; said supporting bed having an elastomer surface engaging and gripping each block; and exit means forwardly of said cutter station and separate from said supporting bed for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the sides of the blocks.

10. In apparatus as defined in claim 1; said drive member including rollers engaging and rolling along said rail as said drive member moves along said rail.

11. In apparatus for facing blocks: an elongate lower supporting bed engageable by the bottom faces of blocks placed thereon; a cutter station at the forward portion of said bed including one or more cutters for cutting one or more horizontal faces of each block; an elongate drive member having adjacent vertical drive pads thereon for engaging a first vertical side of each block to transmit the driving force of said drive member and pads to said first side and feed the blocks forwardly along the bed and across said one or more cutters, whereby a cutting action is performed on one or more horizontal faces of each block; a stationary uninterrupted elongate guide rail disposed parallel to the direction of feed of the blocks and engaged by said drive member and along which said drive member is movable to support said drive member and pads for movement in a fixed vertical plane while said pads are engaging the first side of each block; elongate support means for engaging a second vertical side of each block opposite said first side to maintain the blocks in driving engagement with said pads as said drive member and pads feed the blocks forwardly along the bed and across said one or more cutters; and means supporting said support means in another fixed vertical plane for engagement with the opposite side of each block, whereby said block is clamped between said pads and support means.

12. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces.

13. In apparatus as defined in claim 11; and exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks.

14. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; and exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the sides of the blocks.

15. In apparatus as defined in claim 11; said supporting bed including a row of adjacent parallel bed rollers on which the bottom faces of the blocks rest; said support means including a row of adjacent parallel support rollers rotatable about vertical axes and engaging said second vertical side of each block.

16. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; said supporting bed including a row of adjacent parallel bed rollers on which the bottom faces of the blocks rest; said support means including a row of adjacent parallel support rollers rotatable about vertical axes and engaging said second vertical side of each block; and exit means forwardly of said cutter station and separate from said supporting bed for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks.

17. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; said supporting bed including a row of adjacent parallel bed rollers on which the bottom faces of the blocks rest; said support means including a row of adjacent parallel support rollers rotatable about vertical axes and engaging said second vertical side of each block; exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks; and means engageable with the top face of each block during its passage between said opposed cutters to hold the blocks downwardly against said bed rollers and exit means.

18. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; said supporting bed including a row of adjacent parallel bed rollers on which the bottom faces of the blocks rest; said support means including a row of adjacent parallel support rollers rotatable about vertical axes and engaging said second vertical side of each block; exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks; and spring-pressed roller means rearwardly and forwardly of said top cutter and engageable with the top face of each block during its passage between said opposed cutters to hold the blocks downwardly against said bed rollers and exit means.

19. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; said cutters being rotatable about horizontal axes transversely of the direction of feed of the blocks; the axis of said top cutter being disposed forwardly of the axis of said bottom cutter.

20. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks; and means for adjusting said exit means horizontally to and from said bottom cutter and vertically with respect thereto.

21. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks; and means for adjusting said exit means to and from said bottom cutter and laterally of the direction of feed of the blocks as well as vertically with respect to said bottom cutter.

22. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; said cutters being rotatable about horizontal axes transversely of the direction of feed of action on such faces; saidsupporting bed including a row of adjacent parallel bed rollers on which the bottom faces of the blocks rest; said support means including a row of adjacent parallel support rollers rotatable about vertical axes and engaging said second vertical side of each block; exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks; means for shifting said row of support rollers horizontally relative to said drive member and pads to vary the horizontal distance therebetween; said cutters being rotatable about horizontal axes transversely of the direction of feed of the blocks.

24. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; said supporting bed including a row of adjacent parallel bed rollers on which the bottom faces of the blocks rest; said suport means including a row of adjacent parallel support rollers rotatable about vertical axes and engaging said second vertical side of each block; exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks; means for shifting said row of support rollers horizontally relative to said drive member and pads to vary the horizontal distance therebetween; said cutters being rotatable about horizontal axes transversely of the direction of feed of the blocks; and means for adjusting said exit means horizontally to and from said bottom cutter and vertically with respect thereto.

25. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; said supporting bed including a row of adjacent parallel bed rollers on which the bottom faces of the blocks rest; said support means including a row of adjacent parallel support rollers rotatable about vertical axes and engaging said second vertical side of each block; exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks; means for shifting said row of support rollers horizontally relative to said drive member and pads to vary the horizontal distance therebetween; said cutters being rotatable about horizontal axes transversely of the direction of feed of the blocks; and means for adjusting said exit means to and from said bottom cutter and vertically with respect thereto; the axis of said top cutter being disposed forwardly of the axis of said bottom cutter.

26. In apparatus as defined in claim 11; said drive member including rollers engaging and rolling along said rail as said drive member moves along said rail.

27. In apparatus as defined in claim 1; said drive member comprising chain links, said pads being affixed to said links.

28. In apparatus as defined in claim ll; said drive member comprising chain links, said pads being affixed to said links.

Claims

2. In apparatus as defined in claim 1; and exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the sides of the blocks.

4. In apparatus as defined in claim 1; wherein said supporting bed, drive member and pads and support means are each elongate to simultaneously engage a plurality of blocks and feed such blocks successively toward and through said cutter station.

6. In apparatus as defined in claim 1; wherein said one or more cutters comprise opposed cutters substantially simultaneously engaging opposite Faces of each block which are not engaged by said pads and support means to perform a cutting action on such opposite faces; said supporting bed, drive member and pads and support means each being elongate to simultaneously engage a plurality of blocks and feed such blocks successively toward and through said cutter station; and exit means forwardly of said cutter station and separate from said supporting bed for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the sides of the blocks.

9. In apparatus as defined in claim 1; wherein said one or more cutters comprise opposed cutters substantially simultaneously engaging opposite faces of each block which are not engaged by said pads and support means to perform a cutting action on such opposite faces; said supporting bed, drive member and pads and support means each being elongate to simultaneously engage a plurality of blocks and feed such blocks successively toward and through said cutter station; said pads and support means having elastomer surfaces engaging the sides of each block to grip each block between said pads and support means; said supporting bed having an elastomer surface engaging and gripping each block; and exit means forwardly of said cutter station and separate from said supporting bed for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the sides of the blocks.

22. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; said cutters being rotatable about horizontal axes transversely of the direction of feed of the blocks; and means for tilting said top cutter with respect to said bottom cutter to adjust the axes of said cutters parallel to each other.

23. In apparatus as defined in claim 11; wherein said one or more cutters comprise opposed top and bottom cutters simultaneously engaging the top and bottom faces, respectively, of each block to perform a cutting action on such faces; said supporting bed including a row of adjacent parallel bed rollers on which the bottom faces of the blocks rest; said support means including a row of adjacent parallel support rollers rotatable about vertical axes and engaging said second vertical side of each block; exit means forwardly of said cutter station for supporting the blocks during their passage through the cutter station and with said pads and support means continuing their engagement with the vertical sides of the blocks; means for shifting said row of support rollers horizontally relative to said drive member and pads to vary the horizontal distance therebetween; said cutters being rotatable about horizontal axes transversely of the direction of feed of the blocks.

28. In apparatus as defined in claim 11; said drive member comprising chain links, said pads being affixed to said links.

29. In apparatus as defined in claim 1; said drive member comprising chain links, said pads being affixed to said links; rollers mounted on said links and engaging and rolling along said rail as said links move along said rail.

30. In apparatus as defined in claim 11; said drive member comprising chain links, said pads being affixed to said links; rollers mounted on said links and engaging and rolling along said rail as said links move along said rail.