Tool and apparatus for cutting hard materials
This invention relates to a tool and an apparatus for cutting hard materials, such as for example marble, granite or stone in general, glass, shielded glass, ceramic materials, plastics materials, metals, wood, etc.
In the prior art, apparatuses are known for cutting hard materials, which use cutting tools in the form of a circular rotating blade or in the form of a closed-loop chain. Tools in the form of a circular rotating blade enable only substantially straight cuts to be made and require ,- considerable power to be actuated. jffools in the form of a closed-loop chain normally have the disadvantage that the chain elements that are articulated with one another are free to rotate on a plane in relation to one another, both towards the inside of the loop and towards the outside of the loop. This brings the risk of excessive stress to the elements during cutting operations, due to excessive oscillation, which may also generate resonance phenomena, with consequent great wear to the tools, risk of breakages and imprecision in cutting operations, in particular when cuts along a curved path have to be made.
The object of this invention is to provide a tool and an apparatus for cutting hard materials that enable operating costs and the power required to carry out cutting operations to be reduced, greater cutting speed and quality, with the possibility of obtaining clean profiles without jaggedness on the processed surfaces, less tool wear, fewer risks of breakage, lower operating noise, etc. According to a first aspect of the present invention, a tool is provided for cutting hard materials, comprising a plurality of tool elements connected together to form a closed-loop articulated chain, said tool elements being connected together in such a way as to be able to rotate on a plane in relation
to one another, characterised in that said tool elements are formed in such a way as to be able to rotate in relation to one another only towards the inside of the loop, a rotation towards the outside of the loop being prevented. According to a further aspect of the present invention an apparatus is provided for cutting hard materials, comprising at least one tool, connected to respective actuating means, said tool comprising a plurality of tool elements connected together to form a closed-loop articulated chain, said tool elements being connected together in such a way as to be able to rotate on a plane in relation to one another, characterised in that said tool elements are shaped in such a way as to be able to rotate in relation to one another only towards the inside of said loop, a rotation towards the outside of said loop being prevented.
The invention will now be disclosed with reference to the attached drawings, wherein:
Figure 1 is a side view of a tool and an apparatus according to the invention; Figure 2 is a view from the left of Figure 1;
Figure 3 is a view from above of the apparatus of Figure 1; Figure 4 is a perspective view of a base element of the apparatus of Figures 1, 2 and 3; Figure 5 is a raised view of the base element of Figure 4 ; Figure 6 is a perspective view of an anchoring element of the base element of Figures 4 and 5;
Figure 7 is a cross-section of the anchoring element of Figure 6; Figure 8 is a perspective view of a moving element of the base element of Figures 4 and 5;
Figure 9 is a cross-section of the moving element of Figure 8; Figure 10 a schematic view of a template of the apparatus according to the invention, to guide cutting of the material in the apparatus according to the invention;
Figure 10A is a detail of the template of Figure 10;
Figure 11 is a schematic view of a further embodiment of a template for the apparatus according to the invention;
Figure 11A is a detail of the further embodiment of the template of Figure 11;
Figure 12 is a partial schematic view of a processing tool for the apparatus according to the invention;
Figure 13 is a detail of the tool of Figure 12;
Figures 14 and 15 illustrate further embodiments of the tool of Figures 12 and 13;
Figures 16, 17, 18, 19 and 20 illustrate different embodiments of a guide system of a tool like the one of Figures 12 to 15;
Figure 21 schematically illustrates the fitting of the tool on the spindle-holding head and the relative actuation of the tool;
Figure 22 is a schematic view from below of Figure 21;
Figure 23, 24 and 25 illustrate a connection element between the spindle of the spindle-holding head and the tool;
Figures 26 and 27 illustrate a further embodiment of a template for the apparatus according to the invention.
Figure 28 illustrates a yet further embodiment of a tool according to the invention;
Figures 29 to 32 illustrate details of the tool in Figure 28;
Figures 33 and 34 illustrate fixing means of a tool according to the invention and of the relative actuation on the frame of a machine tool;
Figure 35 and 36 illustrate the fixing of the spindle-holding head motor on a carriage anchored on a fixed template;
Figure 37 schematically illustrates the cutting action of the tool according to the invention when it is guided along the fixed template of Figures 35 and 36.
An apparatus 1 according to the invention comprises a base 2 that is intended to be rested on the material to be cut. On the base 2 two pairs of rails 3 are arranged, on each of which
a respective slide 4 is slidable in both directions. On each slide 4 a respective vertical upright is fixed 5 whereupon a respective further slide 6 is slidable in both directions. A crosspiece is fixed to the slides 6, upon the crosspiece 7 a spindle-holding head 8 is hinged wherein electric, pneumatic or hydraulic motor means (not shown) is installed for the actuation of a spindle 9 that in turn actuates a tool for cutting the material to be processed with the apparatus 1, which will be disclosed below. The spindle 9 is preferably connected to the motor by means of a quick connection actuated by a pneumatic or hydraulic circuit in such a way as to directly transmit motor movement to the tool. The quick connection may be a bayonet fitting, a cam-lock, a plug connection, a slide-slot connection, a bearing connection, a key connection, a taper pin or any other known quick connection.
The base 2 (Figure 4) is equipped with a window 20, through which said tool can carry out cutting operations on the material to be cut. On the bottom face of the base 2 at least one seat is obtained 21 wherein a respective anchoring element 22 is insertable (Figures 6 and 7) to anchor the base 2 to a surface of material to be cut. The anchoring element 22 comprises a body 23, with a shape corresponding to the shape of said seat 21, for example of cylindrical shape. On one of the base faces of said body 23 a preferably circular groove 24 is provided wherein an annular projection 25 of a suction-cup element 26 in elastomeric material is insertable through pressure. Inside the body 23 a first conduit 27 is provided that is connectable to a source of pressurised air that emerges at both ends on the side surface of the body 23. From the first conduit 27 a second conduit 28 branches out, which emerges on the side surface of the body 23 and is connected to a third conduit 29 that discharges onto the bottom of said
suction-cup element 26. The third conduit 29 comprises a first length 29a of small diameter communicating with the second conduit 28 and a second length 29b that emerges at the bottom of the suction cup 26. When the anchoring element 22 is inserted in the respective seat 21, the suction cup 26 is turned towards the outside of the base 2.
To anchor the base 2 to a surface of the material to be processed, the suction cup 26 is rested on said surface and pressurised air is circulated in the first conduit 27. Part of the pressurised air that circulates in the first conduit -27 is channelled into the second conduit 28 and through the Venturi effect causes a vacuum in the third conduit 29, causing the suction cup 26 to stick to the surface of the material to be processed and therefore causing secure anchoring of the base 2 to this surface.
On the bottom face of the base a plurality of further seats 30 is furthermore provided wherein moving means 31 of the base 2 is insertable to shift, where necessary, the base onto the surface of the material to be cut.
Movement means 31 comprises a body 32, with a shape corresponding to the shape of the seat 31, preferably of cylindrical shape. In the body 32, a conduit 33 is obtained comprising a first substantially radial length 33a and a second length 33b that emerges on the face of the body 32 turned to the outside of the seat 30 in which the body 32 is inserted.
By sending a pressurised gaseous fluid into the respective conduits 33 of movement means 31, an air cushion is created underneath the base 2, which enables the base of the surface to be processed to be kept slightly lifted and enables it to be shifted very easily, there being substantially no friction resistance, inasmuch as the air cushion prevents any contact
between the base 2 and the surface of the material to be processed.
The apparatus according to the invention comprises a multiple tool 10, 10a, 10b that is fitted to a guide element, which shall be disclosed hereinafter.
The multiple tool 10, 10a, 10b comprises a series of tool elements 11, 11a, lib, articulated with one another, on each of which cutting means (not shown) is fitted that may comprise a diamond, vidia, very high-speed steel bit etc, depending on the type of material to be cut.
The tool elements 11, 11a, lib are connected to form a closed loop, like a chain. Each element 11, 11a, lib is structured in such a way as to be able to rotate, in relation to the adjacent elements, only towards the inside of said loop, in the direction indicated by arrows F3, F , F5, whilst rotation in the opposite direction, i.e. towards the outside of the loop, is substantially prevented. All this to prevent stresses that develops during cutting operations from causing flexure towards the outside of the loop constituted by the elements 11, 11a, lib, with consequent risk of excessive stress or even of breakages of the articulations between the different loop elements .
In Figure 12 a first embodiment of a tool 10 according to the invention is illustrated, wherein the tool elements 11 are connected to one another in a shapingly coupled manner in such a way that it is not possible to separate the tool elements 11 by exerting traction in the direction of the two arrows FI and F2, but only by exerting traction in a direction that is perpendicular to the plane indicated by the arrows Fl and F2. In Figure 13 a second embodiment of a tool 10a according to the invention is illustrated wherein the tool elements 11a are connected to one another by articulation pins P. In Figure 14 a third embodiment of a tool 10b according to the invention is illustrated, wherein the tool elements lib are
connected to one another by a flexible cable, for example in steel, that passes through respective axial through holes H made in each tool element lib.
The tool 10, 10a, 10b is mounted on a guide element 12-12d that is fixed to the spindle-holding head 8, as will be explained below.
Other embodiments of the guide element 12-12d are shown in Figures 16 to 20. In a first embodiment, illustrated in Figure 16, the guide element 12 has a body 34 equipped with a central window 35 that reduces the friction of the guide element 12 against the material to be cut during the execution of curved cuts. The body 34 furthermore has holes 36 for fixing to the spindle- holding head 8. The body 34 has a substantially rectangular shape with an end with a semicircular shape.
On the edge of the body 34 a seat is obtained, having a "C"- shaped cross-section, wherein a tool 10, 10a, '10b according to the invention is insertable. In Figure 17 a second embodiment of a guide element 12a for a tool 10, 10a, 10b is illustrated.
The guide element 12a comprises a body 34a, with a rectangular central part and ends 42, 42a with a semicircular shape. On the edge of the body 34a a track is obtained wherein a series of idling rollers 38 is obtained to form a loop of rollers 38, whereupon the tool 10, 10a, 10b is arranged. The rollers 38 are actuated to flow in the track by means of the spindle 9, as will be explained below and drag with them the tool 10, 10a, 10b. In Figure 18 a third embodiment of a guide element 12b is illustrated.
The guide element 12b comprises a body 34b with a shape that is the same as that of the body 34 of the first embodiment 12
of the guide element, but however without the central window 35.
On the edge of the body 34b a seat 37b is obtained for accommodating a tool 10, 10a, 10b, that is somehow similar to the seat 37 of the guide element 12.
In the central zone of the body 34b, on both sides of the body, on a central pin 40 two idle discs 39 are mounted, on the side surface of which cutting means is fixed that is somehow similar to cutting means mounted on the tool elements 10, 10a, 10b. The function of the discs 39 with respective cutting means is to facilitate execution of cuts with curved stretches even of a small radius.
Figure 19 illustrates a fourth embodiment of a guide element 12c, that comprises a body 34c of a shape somehow similar to the body 34b of the guide element 12b. On the edge of the body 34c a seat 37c is obtained for accommodating a tool 10, 10a, 10b, that is somehow similar to the seat 37b of the guide element 12b. At the end 40 with a semicircular shape of the body 34c an idle wheel 43 is fitted, on the edge of which a tool 11, 11a, lib inserted into the seat 37c rests. The idling wheel 43 is used to reduce wear to the tool 11, 11a, lib during its movement inside the seat 37c by accompanying the tool along the curved length of the seat 37c at the end 40 of the body 34c. Figure 20 illustrates a fifth embodiment of a guide element 12d, which comprises a body 34d that is somehow similar to the body 34c, of the guide element 12c, or to the body 34b of the guide element 12b. On the edge of the body 34d a seat 37d is obtained for accommodating a tool 10, 10a, 10b, that is somehow similar to the seat 37, 37b, 37c of the guide elements 12, 12b, 12c. At one of the straight stretches of said seat 37d a plurality of idle rollers 44 are arranged the object of which is to reduce friction between the tool 10, 10a, 10b and the surface
of the seat 37d. The idling rollers 44 may also be arranged along the entire length of the straight length and along the curved length of the seat 37d, at the end 40 of the body 34d, or also be arranged along the entire length of the seat 37d. The Figures from 21 to 25 illustrate actuating means of the tool 10, 10a, 10b and the fixing of the guide element 12-12d to the spindle-holding head 8.
The guide element 12-12d is fixed to a flange 45 of the spindle-holding head 8 by means of screws 46 inserted in the respective holes 36 provided in the guide element 12-12d.
Actuation of the tool 10, 10a, 10b inserted in the guide element 12-12d occurs by means of a dragging element 47, insertable on the spindle 9, for example by splined coupling 49. The dragging element 47, at its end 50 opposite the splined coupling 49, is equipped with a peripheral seat 48 wherein the tool elements 11, 11a, lib of the tool 10, 10a, 10b can be inserted. At this end 50 dragging pins 51 are inserted that are arranged along a circumference and which pass through the seat 48.
When the tool elements 11, 11a, lib are inserted in the seat 48, pins 51 engage in the tool elements 11, 11a, lib, in such a way that by rotating the spindle 9, the tool elements 11, 11a, lib are dragged to move by the pins 51. The work position of the spindle-holding head, with a tool 10, 10a, 10b mounted thereupon is rotated by 90° in relation to the position illustrated in Figures 1, 2 and 3. In other words, in the work position the axis of the spindle 9 is arranged in a position that is substantially parallel to the surface of the material whereupon a cutting operation must be performed.
The apparatus according to the invention may be fitted with a template 14, 14a, 14b, illustrated in Figures 10, 10A, 10B,
11, 26 and 27, respectively that serves to guide the tools 10, 10a, 10b during cutting of the material.
A first embodiment 14 of this template is illustrated in Figures 14, 14A, 14B. The template 14 comprises a series of template elements 15 that are connected together by means of joint elements 16. The template elements 15 may comprise, or any way be associated with anchoring elements 22 with suction cup 26, as disclosed above that enable rapid and secure fitting of the template 14 to the surface of the material to be cut. The joint of the template elements 15 enables cuts along any path, even irregular to be achieved to obtain cuts of geometrical figures of any type.
The joint elements 16 comprise a central body 17 wherefrom two shelf elements 18 in the approximate form of an arc of circumference protrude, in each one of which a slot 18a is obtained, wherein a pin 19 engages and is slidable protruding from each template 15 element. The coupling between the pin 19 and the slot 18a enables each template 15 element to rotate in relation to the joint elements 16 adjacent thereto, thereby making a jointed connection between the different template elements 15 of the template 14. This enables the template 14 to be substantially given any type of flat configuration to substantially obtain any cutting configuration of the material be processed. During operations of cutting the material to be processed, a probe follows the lateral profile of the template 14 controlling the shifts of the spindle-holding head, whereupon the cutting tool 10, 10a, 10b is mounted. This enables very accurate cuts to be made. Figures 11, 11A illustrate a second template embodiment 14a wherein the template elements 15a are articulated together by pins 15b.
Each of the template elements has two opposing straight lines, connected to the ends of curved stretches, preferably with the shape of an arc of circumference.
Each of the template elements 15a is preferably associated with an anchoring element 22, to facilitate the fixing of the template 14a to the surface of the material to be cut. Figures 26 and 27 illustrate a third embodiment of template 14b comprising a plurality of template elements 15c articulated together by pins 52. Each template element 15c has a pair of opposite sides, comprising a first side 53 with a curved contour and a second side 54 with a substantially straight contour. The sides 53 and 54 are connected together by curved stretches preferably in the shape of an arc of circumference, with a curvature radius that is substantially less than the curvature radius of the side 53.
The presence of curved sides 53 enables curved cuts of any angle to be achieved with great accuracy.
Figures 28 to 32 show a yet further embodiment of a multiple tool 55 according to the invention in which the tool elements 56 are connected to one another by means of connecting-rod elements 57. The tool elements 56 are rotatingly connected to the connecting-rod elements 57 by means of pins that are not shown that engage in holes 56, 56a of the tool elements 56 and in corresponding holes 57, 57a of the connecting-rod elements 57. The shape of the tool elements 56 is approximately trapezoid, with the larger base turned towards the outside of the closed loop formed by the tool elements 56 and by the connecting-rod elements 57, in such a way that the tool elements 56 can rotate in relation to one another in a substantially free manner towards the inside of the loop, in the direction of the arrow F2, but may rotate only in a very limited manner towards the outside of the loop, in the direction of the arrow FI.
The tool elements 56 are provided with a groove 59 for coupling with a guide element 58 that guides the tool elements 56 in the straight lengths of the closed loop.
The tool 55 is actuated by a toothed drive wheel 60, the teeth 61 of which engage in the spaces between the connecting rods 57. The drive wheel 60 is actuated to rotate by the spindle of the actuating motor of the tool 55. At the end of the loop opposite the drive wheel 60 an idle wheel 62 is arranged, which is similar to the drive wheel 60, the teeth 63 of which also engage in the spaces between the connecting rods 57. The idle wheel 62 is used to guide the multiple tool in one of the curved end lengths of the closed-loop configuration, the tool being guided in the other curved end length by the drive wheel 60. Figure 29 illustrates in greater detail the idle wheel 62, to show the presence therein of radial channels 64 with an arcuate shape that are used to make the lubricating liquid, for example water, reach the bearing 65, by means of which the wheel is fitted to its own rotation axle. The radial channels 64 are used to make lubrication of the bearings 65 simple and effective .
Figures 33 and 34 illustrate the fitting of a tool according to the invention, for example the tool illustrated in Figures 28 to 32, and of the corresponding actuating motor 66 on a support element 67 provided on opposite sides of grooves 68 to be slidingly coupled as a slide on the frame of an apparatus for cutting hard materials. This makes fitting and any replacement of the tools according to the invention on the apparatus very simple and rapid. Figures 35 to 37 show a system for guiding a tool according to the invention in the performance of curved cuts. The main problem that occurs when curved cuts have to be performed is the risk that the tool knocks against one of the cutting walls, due to the curved profile of the walls.
This problem may be solved according to the invention by using a fixed template 69, the external profile of which corresponds to the cutting profile of the curved cut to be carried out. The tool 55 is fitted to a tool holder 76 that is fixed on a carriage 71 with a substantially triangular shape provided with three rolling elements 72, 73, 74, for example rollers, located substantially at the top of said triangular shape. By coupling the carriage 71 with the template 69, the rollers 72 and 73 slide on the external profile 70 whilst the third roller 74 slides on the internal profile 75 of the template 69.
The toolholder 76 is connected to the carriage 71 in such a way that during the movement of the carriage 71 along the template 69 to perform the cut the tool 55 is tilted in relation to the tangent towards the external profile 70 of the template 69.
In this way, as illustrated in figure 37, the tool 55 is tilted in relation to the walls 78, 79 of the cut 77, which facilitates penetration of the tool 55 into the material to be cut and prevents the tool 55 from knocking against the walls of the cut 77 during its movement in the direction of the arrow F3.
The template 69 may also have a straight profile to create straight cuts. In this case, the carriage 71 may also have a substantially rectangular shape, with four rolling elements, or another shape that is suitable for sliding on the straight template.
The template 69 may also have a straight profile to achieve straight cuts. In this case the carriage 71 may also have a substantially rectangular shape, with four rolling elements or another shape that is suitable for sliding on the straight template .
In the practical embodiment, the materials, dimensions and construction details may be different from those indicated but
be technically equivalent, without thereby leaving the juridical domain of the present invention.