STONE MATERIAL PRODUCTS

Field of the invention

[0001] The present invention generally finds application in the field of working of materials with high surface hardness, and particularly relates to a machine for working products made of stone or stone-like materials.

[0002] The invention also relates to a modular system for working stone materials.

Background art

[0003] Machine tools are known to be used, in the field of processing materials with high surface hardness, for carrying out honing, polishing, scratching, drilling, brushing, calibrating or similar processes thereupon.

[0004] The products to be processed may be either slabs of stone or granite, or prefabricated concrete items, prefabricated panels made of concrete, conglomerates, composites or other similar materials.

[0005] Generally, these machines comprise a bridge structure overlying a stationary support table for the products to be processed and defining a working area.

[0006] Particularly, the bridge structure is designed to move within the working area in a longitudinal direction and comprises a horizontal beam which is placed above the support table and is adapted to slidably support a carriage moving in a transverse direction.

[0007] The carriage may have two or more tool-holding heads mounted thereto, which are designed to interact with the block or slab of stone to perform one or more stone-working processes thereon.

[0008] Nevertheless, these machines can only process one product at a time and also require it to be manually handled from the support table.

[0009] In an attempt to at least partially obviate these drawbacks, machines are known for processing products of stone or stone-like materials which comprise a plurality of modules or workstations for performing multiple independent and simultaneous stone-working processes on different products. [0010] For example, FR81 1 3646 discloses a machine for milling stone products, which comprises a monolithic load-bearing structure defining a plurality of adjacent workstations, each having a stationary support table for the stone slabs.

[0011 ] The load-bearing structure comprises a carriage for each station, having at least one tool-holding head that is designed to move above the corresponding work table in longitudinal and transverse directions.

[0012] Particularly, each workstation may be designed to perform a single type of process on the product.

[0013] Nevertheless, a first drawback of this arrangement is that the work tables of each station are not connected by slab transferring means.

[0014] Thus, at the end of each process, the slabs must be manually removed and/or displaced to the support table of the station adjacent thereto to perform the next stone-working process thereon.

[0015] A further drawback is that distinct stone-working processes are very complex to perform on the entire length of the block or portions thereof, in this machine.

[0016] This is because they will require the slab to be manually carried from one station to the next as many times as the processing steps that are required to be carried out on the block.

[0017] Therefore, the overall block or slab processing times are still very long in this solution, especially when a great number of processes must be performed.

[0018] Furthermore, the manual transfer of the block from one station to the next often requires the head to be centered again relative to the block to afford high-precision processing, within predetermined tolerances.

[0019] Therefore, a high level of skill and expertise is required of the operator to perform a plurality of accurate stone-working processes with this machine.

[0020] Nevertheless, even a highly skilled operator can only partially reduce the risk of obtaining waste or non-conforming products due to manual transfer between stations. Disclosure of the invention

[0021 ] The object of the present invention is to overcome the above drawbacks, by providing a machine for processing products made of stone or stone-like materials, that is highly efficient and relatively cost-effective.

[0022] A particular object of the present invention is to provide a machine for processing products made of stone materials that can reduce the overall time required for processing the material.

[0023] A further object of the present invention is to provide a machine for processing products made of stone materials that can improve the accuracy of the stone-working processes performed on the material.

[0024] Another object of the present invention is to provide a machine for processing products made of stone materials that is entirely automated, to minimize any manual work that the operator may be required to perform on the product to be processed.

[0025] A further object of the present invention is to provide a machine for processing products made of stone materials that can dramatically reduce the number of waste or non-conforming pieces.

[0026] Yet another important object of the present invention is to provide a machine for processing products made of stone materials, that can perform high-precision, accurate stone-working processes on the products, even when used by operators having no special skill.

[0027] These and other objects, as better explained hereafter, are fulfilled by a machine for processing products made of stone materials as defined in claim 1 .

[0028] In a further aspect, the invention relates to a modular system for working stone materials, as defined in claim 10.

[0029] Advantageous embodiments of the invention are defined in accordance with the dependent claims.

Brief Description of the Drawings

[0030] Further characteristics and advantages of the invention will be more apparent upon reading of the detailed description of a few preferred embodiments of a machine and a modular system for processing products made of stone materials, which are described as non-limiting examples with the help of the annexed drawings, in which:

FIG. 1 is a perspective view of a machine for processing products made of stone materials according to the invention in a first configuration;

FIG. 2 is a perspective view of a first detail of Fig. 1 ;

FIG. 3 is a broken-away front view of the machine of Fig. 1 ;

FIG. 4 is a broken-away lateral view of the machine of Fig. 1 ;

FIG. 5 is a perspective view of a second detail of Fig. 1 ;

FIG. 6 is an enlarged perspective view of Fig. 5;

FIG. 7 is a perspective view of a modular system for processing products made of stone materials which comprises a pair of machine tools of the invention, in a second configuration.

Detailed description of a preferred embodiment

[0031 ] Referring to the accompanying figures, there is shown a machine for processing products made of stone or stone-like materials, which is generally designated by numeral 1 , and is designed to perform processes on the surface S of different products P.

[0032] The machine 1 may be used either for processing of stone or granite blocks or slabs, or for processing of prefabricated concrete items and/or panels made of concrete, conglomerates, composites or other similar materials.

[0033] In the particular configuration of the invention as shown in the figures, the machine 1 may be particularly adapted to perform stone-working processes on products P formed by juxtaposing a plurality of tiles Q made of stone materials.

[0034] In its basic form, as best shown in FIGGS. 1 and 2, the machine 1 comprises a support surface 2 which extends in a first longitudinal direction L for supporting the products P being processed and a plurality of working modules 3 each comprising a toolholder head 4 which is designed to carry out a respective processing step on a product P, and a corresponding working area 5 of the support surface 2.

[0035] The support surface 2, as best shown in FIG. 1 , is adapted to support the product P to be processed within a corresponding working area 5 while the corresponding toolholder head 4 is processing it.

[0036] The modules 3 are arranged in side-by-side and equally spaced positions, with a predetermined pitch s along the first longitudinal direction L.

[0037] Particularly, each module 3 may be spaced from the adjacent module 3 at a substantially constant pitch s.

[0038] The toolholder heads 4 may be adapted to process the product P by a single type of stone-working process, selected from the group comprising milling, leveling, bush-hammering, flaming, scratching or the like.

[0039] Furthermore, each head 4 may be designed to have a single processing tool mounted thereon, thereby avoiding automatic tool changing.

[0040] According to a peculiar aspect of the invention, the support surface 2 is designed to move stepwise along the first longitudinal direction L with steps having the same magnitude w as the pitch s, to bring the products P situated in each working area 5 to the adjacent working area 5 when the toolholder head 4 of each module 3 has completed the corresponding processing step.

[0041 ] Due to this feature, the products P to be processed, that are located on the support surface 2 will remain in the corresponding working areas 5 during the processing steps that are performed by toolholder heads 4 and will automatically and synchronously move into the adjacent working area 5 as soon as all such processing steps have been completed.

[0042] Conveniently, the products P to be processed may be manually or automatically placed on the support surface 2 and may be longitudinally spaced by a distance di that is substantially equal to the pitch s of the modules 3.

[0043] As best shown in FIGS. 1 to 4, the machine 1 may comprise a frame 6 which is adapted to support the plurality of toolholder heads 4 of adjacent modules 3.

[0044] Particularly, the frame 6 may comprise at least two pairs of longitudinally offset and equally spaced uprights 7, 8, which are joined at their tops by a pair of longitudinal beams 9. [0045] Furthermore, each pair of uprights 7,8 may be mutually joined by a pair of cross members 1 0.

[0046] Conveniently, a single frame 6 may contain multiple processing modules 3 therein, in side-by-side arrangement along the first longitudinal direction L.

[0047] In the particular configuration of the invention as shown in the figures, the machine 1 comprises three modules 3 and three corresponding toolholder heads 4.

[0048] The frame 6 may comprise a pair of substantially parallel longitudinal guides 1 1 , as best shown in FIG. 3, which are secured to the beams 9 and are adapted to slidably support a first bridge structure 1 2.

[0049] Conveniently, the longitudinal guides 1 1 may be secured to the inner faces 1 3 of the beams.

[0050] Furthermore, the first bridge structure 1 2 may comprise a plurality of first wheels 14, as shown in FIG. 3, which are idly mounted to respective first axles 1 5 to rotate on the longitudinal guides 1 1 about respective transverse axes of rotation R-i .

[0051 ] Conveniently, the first bridge structure 1 2 may comprise a pair of longitudinally staggered and substantially parallel transverse guides 1 6 for slidably guiding along a second transverse direction T substantially orthogonal to the first direction L a second bridge structure 1 7, on which the toolholder heads 4 associated to the corresponding working areas 5 enclosed within the frame 6 are secured.

[0052] The first bridge structure 1 2 may comprise a pair of transverse beams 18, having the transverse guides 1 6 secured thereto.

[0053] Furthermore, the second bridge structure 1 7 may comprise a plurality of second wheels 1 9, as shown in FIG. 4, which are idly mounted to respective second axles 20 to rotate on the second transverse guides 1 6 about respective longitudinal axes of rotation R ₂ .

[0054] In the illustrated configuration of the invention, the second bridge structure 1 7 may cause the toolholder heads 4 to simultaneously move in one way along the first longitudinal direction L and/or the second transverse direction T within their respective working areas 5.

[0055] Alternatively, in a different configuration of the invention, not shown, the second bridge structure 1 7 may be configured to cause the toolholder heads 4 to move independently within their corresponding working areas 5.

[0056] Particularly, the machine 1 may comprise a plurality of electric motors 21 , 22, some of which are visible in FIG. 4, which are associated with the first 12 and second 1 7 bridge structures to promote controlled translation thereof along their respective longitudinal L and transverse T directions such that the toolholder heads 4 can be moved into their respective working areas 5.

[0057] For example, the electric motors 21 , 22 may promote the controlled movement of the first 1 2 and second 1 7 bridge structures such that the toolholder heads 4 can move into their respective working areas 5, along horizontal, diagonal, zigzag, diagonal, spiral, or similar paths.

[0058] Furthermore, continuous dot-like or hatched processing may be performed on the product along the direction of movement of the toolholder heads 4.

[0059] Preferably, at least one toolholder head 4 may be designed to move in a third substantially vertical direction V and/or to rotate about respective substantially horizontal R ₃ and/or vertical R ₄ axes of rotation.

[0060] Advantageously, as best shown in FIGS. 1 , 3 and 4, the support surface 2 may be defined by a substantially longitudinal conveyor 23 operated by controlled power means, not shown, controlled and synchronized with the toolholder heads 4.

[0061 ] Particularly, the power means may comprise one or more motors connected to the central control unit, not shown, for controlling the operation of the toolholder heads 4.

[0062] Preferably, as clearly shown in FIGS. 1 , 3 and 4, the support surface 2 may be substantially horizontal and capable of moving along the first longitudinal direction L in both ways.

[0063] Thus, at the end of the processing steps, a given product P may move stepwise along the longitudinal direction from a given working area 5 to an adjacent working area 5 upstream or downstream therefrom.

[0064] Advantageously, as best shown in FIGS. 1 , 5 and 6, the machine 1 may comprise holding means 24 associated with each working area 5 to hold the products P to be processed on the support surface 2 while each toolholder head 4 is carrying out its processing steps.

[0065] Particularly, the holding means 24 may be stationary relative to the support surface 2 and may be preferably secured to the ground G or the frame 6 of the machine 1 .

[0066] At each working area 5, the holding means 25 may comprise, as clearly shown in FIG. 5, a pair of transverse clamps 25 and a pair of longitudinal clamps 26, which are designed to interact, respectively, with the transverse B and longitudinal B' edges of the products P being processed.

[0067] Particularly, a pair of transverse clamps 25 and a pair of longitudinal clamps 26 may be provided for each working area 5.

[0068] Furthermore, the transverse 25 and longitudinal 26 clamps of two adjacent working areas 5 may be longitudinally separated by a distance d2 that is equal to the pitch s.

[0069] Preferably, the clamps 25, 26 may be formed using a substantially rectangular metal profile 27 having a substantially vertical planar end edge 28.

[0070] Particularly, as schematically shown in FIG. 6, during processing of juxtaposed tiles Q, the end edge 28 of the clamps 25, 26 will be designed to interact with the corresponding side edge B, B' of the product P, to prevent the latter from being longitudinally or transversely displaced during an action of a toolholder head 4 in a corresponding working area 5.

[0071 ] Conveniently, as clearly shown in FIG. 5, the pair of transverse clamps 25 and the pair of longitudinal clamps 26 may be designed to move along the vertical and transverse directions respectively relative to the support surface 2.

[0072] Thus, the transverse 25 and longitudinal 26 clamps will be adapted to engage/disengage the products P to be processed and to allow stepwise displacement thereof along the first longitudinal direction L. [0073] The holding means 24 may comprise first actuators 29 for promoting the vertical movement of the transverse clamps 25 and second actuators 30 for promoting the transverse movement of the longitudinal clamps 26.

[0074] In the illustrated configuration of the invention, the first 29 and second 30 actuators may be hydraulic actuators and may comprise a pair of pistons 31 moving in respective vertical V and transverse T' directions, for each clamp 25, 26.

[0075] In a further aspect, as shown in FIG. 7, the invention relates to a modular system 32 for processing stone materials, which comprises a processing line 33 with at least two frames 6 arranged one after the other in a first longitudinal direction L.

[0076] Each frame 6 of the line 33 comprises a plurality of working modules 3, which are longitudinally spaced with the predetermined pitch s and define respective working areas 5 for the products P to be processed.

[0077] Each module 3 comprises a toolholder head 4, which is adapted to carry out a respective processing step on a product P located in the corresponding working area 5, a longitudinal support surface 2 being further provided for the products P to be processed within the working areas 5 of the modules 3.

[0078] According to a peculiar feature of the invention, the support surface 2 is designed to move stepwise along the line 33 with steps having the same magnitude w as the pitch s, to bring the products P situated in each working area 5 to the adjacent processing area 5, when the head 4 of each module 2 has completed the corresponding processing step.

[0079] Conveniently, the frame 6 of each machine 1 may comprise two pairs of uprights 7, 8, joined by a pair of longitudinal beams 9 that support a first bridge structure 12, the latter being adapted to slide on longitudinal guide means 1 1 secured to the longitudinal beams 9.

[0080] Particularly, the distance d3 between two modules 3 of two adjacent machines 1 along the line 33 will be equal to the pitch s or to a multiple thereof, for the products P to be properly positioned within the corresponding working areas 5. [0081] The above disclosure clearly shows that the machine tool and the modular system fulfill the intended objects and particularly meet the requirement of reducing the overall product processing times and improving processing accuracy.

[0082] The machine and system of the invention are susceptible to a number of changes or variants, within the inventive concept disclosed in the appended claims.

[0083] All the details thereof may be replaced by other technically equivalent parts, and the materials may vary depending on different needs, without departure from the scope of the invention.

[0084] While the machine and system have been described with particular reference to the accompanying figures, the numerals referred to in the disclosure and claims are only used for the sake of a better intelligibility of the invention and shall not be intended to limit the claimed scope in any manner.

Industrial applicability

[0085] The present invention may find application in industry, because it can be produced on an industrial scale in factories for manufacturing machine tools for stone processing.