Cross-Reference to Related Applications

This patent application is related to Italian Patent Application No. 102021000011354 filed on May 4, 2021, the entire disclosure of which is incorporated herein by reference .

Technical Field of the Invention

The present invention relates to a manufacturing system and a method for manufacturing articles made of compacted ceramic powder.

State of the Art

In the field of production of ceramic products, in particular of ceramic slabs and tiles, there are known production plants which supply (typically, in a substantially continuous manner) semi-dry ceramic powder (i.e., with a moisture content of below 10%, in particular ranging from 5% and 6%) along a given path through a continuous compaction assembly, which subjects the ceramic powder to a compaction pressure, so as to obtain a layer of compacted ceramic powder in the form of continuous strip of compacted ceramic powder, which is subsequently cut to obtain a plurality of articles made of compacted ceramic powder, having different sizes based on the type of ceramic product to be obtained, which will then be dried, possibly decorated, and fired to obtain the final ceramic products.

In detail, cutting of the continuous strip of compacted ceramic powder takes place while the strip is moving towards the subsequent processing stations. Therefore, during the cutting operations, imperfections along the borders of the articles made of compacted ceramic powder, typically of the portions of compacted ceramic material in excess that protrude with respect to the borders of the articles, the so-called burrs, can occur due to imprecisions during cutting.

Therefore, known production plants of ceramic products are provided with finishing stations, also called deburring or trimming stations, at which the borders of the articles made of compacted ceramic powder are finished (or deburred) to eliminate the aforesaid burrs. In detail, the finishing operations of the transverse and longitudinal borders of the articles made of compacted ceramic powder are carried out by means of abrasive tools that intercept the border to be treated, remove any excess material and bevel the edges of this border.

Each of these abrasive tools is typically mounted on a linear guide arranged above the conveyor device intended to transport the articles made of compacted ceramic powder from the cutting station towards the subsequent processing stations, so that this abrasive tool moving along the respective linear guide can intercept and finish (i.e., deburr or trim) at least one border of an article made of compacted ceramic powder, when this article is above the conveyor device at the finishing station, so as to finish this border, that is, so as to remove any excess material (namely, the so-called burrs) from said border and to bevel the edges of this border.

To finish (i.e., deburr or trim) all the borders of each article made of compacted ceramic powder, the finishing assembly generally has two linear guides arranged parallel to the moving direction of the articles made of compacted ceramic powder to finish (i.e., deburr) the lateral borders of each article made of compacted ceramic powder while it moves (moved by the conveyor device) in the moving direction; and at least one further linear guide arranged crosswise to the moving direction to finish the front borders of the same article, when this is in a first position, and the rear borders of the article, when this is in a second position. Processing of the transverse borders of each article made of compacted ceramic powder is more complex and requires more time with respect to the longitudinal borders. In fact, typically at least during processing of the lower transverse borders, the article made of compacted ceramic powder is stopped at the first position at least for the time required by the abrasive tool to process the front borders and in the second position for the time required by the abrasive tool to process the rear borders. In this context, the finishing (i.e., deburring) stations risk representing a bottleneck for the manufacturing plant of ceramic products.

In an attempt to better manage these finishing operations of the transverse borders, the known plants are generally provided with multiple finishing stations, each having at least one linear guide and one abrasive tool, so that the articles of ceramic powder exiting from the cutting station are sorted among the various finishing stations so as to simultaneously finish several articles made of compacted ceramic powder. However, modern ceramic product production plants (that is, modern compacting and cutting machines) are able to reach very high productivity values, in terms of workpieces per minute, of up to around 40-70 workpieces per minute.

To be able to manage such high volumes, the known plants would require a number of finishing (i.e., deburring) stations such as to occupy enormous amounts of space, in the order of 1000 m ² . In fact, this makes this solution inapplicable.

Added to the drawbacks described above are those linked to the fact that the articles made of compacted ceramic powder exiting from the cutting station are not always perfectly rectangular parallelepipeds and do not always reach the aforesaid finishing station perfectly aligned with one another and with the transverse borders perfectly perpendicular to the moving direction. In detail, due to imprecisions in the cutting station the transverse borders of the articles made of compacted ceramic powder might not be perfectly parallel to one another; moreover, during their movement on the conveyor device these articles of ceramic powder could move or rotate with respect to the moving direction, especially if the conveyor device is of the roller type. This could compromise the success of the transverse finishing operations as the abrasive tool (moving on a path defined by the linear guide) would risk removing different amounts of material along a same border based on the inclination with which each article reaches the finishing station.

Other systems for the production of ceramic products of a known type that provide for finishing of the borders of the ceramic products are, for example, of the type described in the patent CN110227979. Finishing systems of articles of another type are, for example, described in the document CN102079057, which relates to a method and a device for processing glass substrates.

The object of the present invention is to provide a manufacturing system and a method for manufacturing articles made of compacted ceramic powder, with which it is possible to at least partially overcome the drawbacks of the known art.

Subject and Summary of the Invention In accordance with the present invention, a manufacturing system and a method for manufacturing articles made of compacted ceramic powder are proposed for the manufacturing of articles made of compacted ceramic powder as set forth in the appended independent claims, and preferably, in any one of the claims dependent, directly or indirectly, on the aforesaid independent claims.

The claims describe preferred embodiments of the present invention forming an integral part of the present description.

Brief Description of the Drawings The invention is described below with reference to the accompanying drawings, which illustrate some non-limiting embodiments thereof, wherein:

- Fig. 1 represents a schematic side view of a manufacturing system of articles made of compacted ceramic powder according to the present invention;

Figs. 2 to 5 and 4A are plan views of a part of the manufacturing system of Fig. 1 in accordance with different embodiments of the present invention; - Fig. 6 is a perspective view on an enlarged scale of the finishing/deburring device, used in the embodiments illustrated in Figs. 2-5 and 4A, while it finishes a transverse border of an article made of compacted ceramic powder; and

- Fig. 7 is a plan view of a part of the manufacturing system of Fig. 1 in accordance with a further embodiment of the present invention.

Detailed Description of Preferred Embodiments of the Invention

In the accompanying figures, the reference number 1 indicates as a whole a manufacturing system of articles made of compacted ceramic powder MCP.

In particular, in the present description, the expression "finish articles made of compacted ceramic powder" means to trim, or deburr, articles made of compacted ceramic powder MCP, namely, to remove portions of material from one or more borders 2, 2', 2’’ and 2’’’ of one or more articles made of compacted ceramic powder MCP. In detail, advantageously but without limitation, the removal of these portions of material is aimed at bevelling the upper and lower edges 13, 13' of the borders 2, 2', 2’’ and 2’''. In even more detail, advantageously, but without limitation, these portions of material to be removed have an extension that is at most around 3 mm, in particular at most around 2.5 mm and, advantageously, but without limitation, comprise (in particular, are made up of) parts of material in excess, also called burrs (not visible in the accompanying figures and which can be created as a result of imprecisions in the operations for the production of the ceramic articles), and/or additional parts of the (body) of the article made of compacted ceramic powder MCP. Therefore, the finishing operations that will be referred to in the present description must be understood as operations for the removal of portions of material, the extension of which is advantageously, but without limitation, at most around 3 mm, in particular at most around 2.5 mm, from one or more borders 2, 2', 2’’ or 2’’’ of an article made of compacted ceramic powder MCP.

With particular reference to Fig. 1, advantageously, but without limitation, the manufacturing system lof articles made of compacted ceramic powder MCP comprises: a supply assembly 3, advantageously provided with at least one dispensing device (of a known type and not further described herein) and, configured to supply a given amount (namely, a mass) of (uncompacted) ceramic powder CP at an input station 4; a compaction device 5, arranged at a compaction station 6, and configured to apply a compaction pressure to the (uncompacted) ceramic powder CP so as to compact the ceramic powder CP and obtain a layer of compacted ceramic powder KP; and a conveyor assembly 7 to transport the ceramic powder CP along a given path P in a moving direction A from the input station 4 to the compaction station 6 and the layer of compacted ceramic powder KP from the compaction station 6 to a cutting station 8, where the articles made of compacted ceramic powder MCP are formed. According to some advantageous, but non-exclusive, embodiments (such as the one illustrated in Fig. 1), the conveyor assembly 7 comprises at least one conveyor device 9 arranged and configured to receive the (uncompacted) ceramic powder CP at the input station 4 and transport it (in a substantially continuous manner) up to the compaction station 6, where the layer of compacted ceramic powder KP is formed, and to then transport this layer of compacted ceramic powder KP up to (in particular, to the exit of) the cutting station 8 along a first section PA of the given path P. Even more in detail, advantageously but without limitation, the conveyor device 9 comprises (in particular, is made up of) a conveyor belt that extends (and configured to move) from the input station 4 to the (end of the) cutting station 8, passing through the compaction station 6, along the section PA of the given path P.

According to some non-limiting embodiments (such as the one schematically illustrated in Fig. 1), the compaction device 5 comprises (in particular, is made up of) a continuous compaction assembly arranged along the section PA of the given path P. In particular, this continuous compaction assembly comprises at least two compression rollers 10 arranged on opposite sides of (in particular, one above and one below) the conveyor device 9 (in particular, of the conveyor belt) to exert a pressure on the (uncompacted) ceramic powder CP so as to compact said (uncompacted) ceramic powder CP and obtain the layer of compacted ceramic powder KP.

Furthermore, advantageously, but not necessarily (as illustrated, for example, in Fig. 1), the continuous compaction assembly comprises a pressure belt 11 that converges towards the conveyor device 9 (in particular, towards the conveyor belt) in the moving direction A so as to exert a pressure (from the top down) that gradually increases in the direction A on the ceramic powder CP in order to compact it as it moves along the section PA of the given path P. In particular, the pressure belt 11 is made (mainly) of metal (steel) so that it cannot be substantially deformed while pressure is exerted on the ceramic powder CP. According to specific non-limiting embodiments (such as the one illustrated in Fig. 1), in this case, the continuous compaction assembly also comprises an opposing belt 11', advantageously made of rubber or a similar material, arranged on the opposite side of the conveyor device 9 (in particular, of the conveyor belt) with respect to the pressure belt 11 to cooperate with the conveyor device 9 (in particular, with the conveyor belt) to provide a suitable opposition to the downward force exerted by the pressure belt 11. In these cases, in particular, the opposing belt 11' is (mainly) made of metal (steel) so that it cannot be substantially deformed while pressure is exerted on the ceramic powder CP. According to some embodiments, not illustrated, the opposing belt 11' and the conveyor device 9 (in particular, the conveyor belt) coincide. In other words, the conveyor device 9 (in particular, the conveyor belt) is (mainly) made of metal (steel) and the opposing belt is absent. Advantageously, but without limitation, the manufacturing system 1 of articles made of compacted ceramic powder MCP also comprises at least one cutting device 12 arranged at the cutting station 8 and which is configured to cut, at least crosswise, namely, at least along a direction B transverse to the moving direction A, the layer of compacted ceramic powder KP in order to obtain a plurality of articles made of compacted ceramic powder MCP. According to some advantageous, but non-limiting, embodiments, the cutting device 12 comprises at least one cutting blade (not illustrated) configured to come into contact with the layer of compacted ceramic powder KP and to cut it, in particular this blade during the cut is operated to move along the cross direction B.

According to some advantageous, but non-limiting, embodiments, the cutting device 12 is also configured to cut the layer of compacted ceramic powder KP also parallel to the moving direction A in order to obtain groups G of articles, each comprising (in particular, made up of) at least two articles made of compacted ceramic powder MCP at least partially arranged next to one another along the cross direction B (see in particular Figs. 3, 4, 4A and 5 where these groups G of articles are illustrated while they exit from the cutting station 8 and move towards a deburring/trimming station 16, which will be better described in the following). In other words, advantageously, but not necessarily, the cutting device 12 can give rise to different formats of articles made of compacted ceramic powder MCP. In detail, the layer of compacted ceramic powder KP can only be cut crosswise, namely, only along (i.e., parallel to) the cross direction B, so as to give rise to articles of ceramic powder MCP of large size

(intended to form ceramic slabs of large size, for example having a section of 1200/1800 x 2400/3600mm), as illustrated in Figs. 2 and 7, or of smaller size (intended to form ceramic tiles, for example having a section from 900/1200xl800/2000mm, up to 400x400mm) which are conveyed along the given path P organized in the aforesaid groups G of articles, also called sets, as illustrated in Figs. 3, 4, 4A and 5.

In the present description, the expression "articles made of compacted ceramic powder MCP" is meant as articles made of compacted ceramic powder MCP not yet fired; in other words, "articles made of compacted ceramic powder MCP" is meant as portions of the layer of compacted ceramic powder KP obtained by cutting this layer of compacted ceramic powder KP, optionally but not necessarily treated, for example by means of heat treatments, such as drying, and/or by means of decorative treatments etc., but not yet subjected to firing. Each of these articles made of compacted ceramic powder MCP is provided with two transverse borders 2, 2', namely, which extend substantially crosswise to the moving direction A (when the article made of compacted ceramic powder MCP is on the conveyor assembly 7), and two longitudinal borders 2’’ and 2’'', namely, which extend substantially along the moving direction A (when the article made of compacted ceramic powder MCP is on the conveyor assembly 7). Each of these borders 2, 2', 2’’ and 2’’’ is advantageously provided with an upper edge 13 and with a lower edge 13'. Furthermore, advantageously, but without limitation, the transverse borders 2 and 2’ are substantially parallel and opposite one another and the longitudinal borders 2’’ and 2’’’ are substantially parallel and opposite one another and orthogonal to the transverse borders 2 and 2’. According to other embodiments, not illustrated, the angle that remains defined between the adjacent borders 2, 2’', 2’’’ and 2’ of each article made of compacted ceramic powder MCP could be (albeit slightly) different from a right angle.

Advantageously, but without limitation, the aforesaid conveyor assembly 7 is configured to move these articles made of compacted ceramic powder MCP (optionally organized in groups G of articles, as explained above) along the given path P, in particular along a further section PB of the given path P, from the cutting station 8 to an output station 14. Advantageously, but without limitation, the given path P that goes from the input station 4 to the output station 14 comprises (in particular, is made up of) sections PA and PB described positioned one after another continuously, namely, without interposition of other sections.

According to some advantageous, but non-limiting, embodiments (such as those illustrated in Figs. 1 to 4, 4A and 6), the aforesaid conveyor assembly 7 comprises at least one roller conveyor 15 which is arranged and configured to receive (in particular, from the conveyor device 9) the articles made of compacted ceramic powder MCP (and/or the groups G of articles), or a part thereof, and transport them (in a substantially continuous manner) at least up to a deburring/trimming station 16 along this section PB of the given path P; even more advantageously up to the output station 14, passing through the aforesaid deburring/trimming station 16 and through at least one detection station 17.

In detail, according to some advantageous but non-limiting embodiments (such as those illustrated in Figs. 1 to 5 and 7), the roller conveyor 15 comprises (in particular, is made up of) a plurality of rollers 18 which extend along (or parallel to) the cross direction B and are arranged in succession along the moving direction A.

It is understood that according to alternative embodiments, not illustrated, the roller conveyor 15 could be replaced by any other type of conveyor, for example a belt conveyor, arranged and configured to receive (in particular, from the conveyor device 9) the articles made of compacted ceramic powder MCP (and/or the groups G of articles), or a part thereof, and transport them (in a substantially continuous manner) at least up to a deburring/trimming station 16 along this section PB of the given path P; even more advantageously up to the output station 14, passing through the aforesaid deburring/trimming station 16 and through the detection station 17.

Advantageously, but without limitation, the articles made of compacted ceramic powder MCP (and/or the aforesaid groups G of articles) move along the conveyor assembly 7, in particular along the roller conveyor 15, and are moved towards (into) the deburring/trimming station 16 spaced from one another by a given distance value, which varies based on the format of the articles made of compacted ceramic powder MCP so as to eliminate the risk of an article made of compacted ceramic powder MCP, or a group G of articles, reaching the deburring/trimming station 16 before the article made of compacted ceramic powder MCP, or the group G of articles, previously finished (i.e., deburred/trimmed) has been moved to exit from this deburring/trimming station 16. In particular, advantageously, but without limitation, the given distance value is at least equal to around 15cm, in particular is at least equal to around 20cm.

According to some non-limiting embodiments, this given distance value between successive articles made of compacted ceramic powder MCP (and/or between the groups G of articles) at least along the section PB of the given path P is guaranteed by varying, in a known manner the speed of movement of at least part 180 of the rollers 18 of the roller conveyor 15, upstream of the deburring/trimming station 16 along the section PB of the given path.

According to alternative, non-limiting, embodiments, the conveyor assembly 7 comprises a further adjustment conveyor 180, advantageously with rollers, arranged between the conveyor device 9 and the roller conveyor 15 and configured to impart the speed and the necessary distancing to the articles made of compacted ceramic powder MCP (and/or to the groups G of articles) that move along the section PB of the given path P towards the deburring/trimming station 16.

Advantageously (as illustrated schematically in Fig. 1), the manufacturing system 1 also comprises a deburring/trimming assembly 19 which is arranged at the deburring/trimming station 16 and is configured to finish (in particular, deburr/trim) at least a first border 2, which is transverse to the moving direction A of each one of the articles made of compacted ceramic powder MCP which, in use, moves individually or in groups G of articles, along the conveyor assembly 7, in particular along the roller conveyor 15.

Advantageously, but without limitation (as illustrated in the accompanying figures), the deburring/trimming station 16 is located downstream of the cutting station 8 along the given path P, in particular along the section PB of the given path

P.

Advantageously, but without limitation (as illustrated in the accompanying figures), the deburring/trimming assembly 19 comprises at least one abrasive tool 20 configured to intercept and finish (namely, deburr/trim) the aforesaid border 2, and a support structure 22 which carries the abrasive tool 20 and can be operated, by a control assembly 21, to move the abrasive tool 20 along a deburring/trimming trajectory T (represented schematically with a dashed line in Fig. 6).

With particular reference to Fig. 6, advantageously, but without limitation, the abrasive tool 20 comprises (in particular is made up of) a pair of truncated cone grinders 23 arranged opposite and at a given distance from each other so as to receive therebetween and, in use, finish (in particular, deburr/trim) a border 2, 2’ to be treated.

Advantageously, but without limitation, these truncated cone grinders 23 are configured to be able to take, in use (that is, when the abrasive tool 20 is moved along the deburring/trimming trajectory T or the further deburring/trimming trajectory T), a position with respect to the border 2 or 2’ to be treated such as to allow finishing (in particular, deburring/trimming) both of the upper edge 13 and of the lower edge 13' of this border 2 or 2’ (that is, removal of the aforesaid portions of material both from the upper edge 13 and from the lower edge 13' of this border 2 or 2'). In detail, when the conveyor assembly 7 comprises the roller conveyor 15, the truncated cone grinders 23 are sized to be able to be inserted, in use (that is, when the abrasive tool 20 is moved along the deburring/trimming trajectory T or the further deburring/trimming trajectory), between two successive rollers 18 of the roller conveyor 15.

According to some advantageous, but non-limiting, embodiments (such as those illustrated in Figs. 4 and 4A), the deburring/trimming assembly 19 comprises at least a further abrasive tool 20' (similar to the abrasive tool 20 and) configured to intercept and finish (in particular, deburr/trim) a further border 2', opposite the border 2, and a further support structure 22' which (is similar to the support structure 22,) carries the further abrasive tool 20' and can be operated, by the control assembly 21, to move the further abrasive tool 20' along a further deburring/trimming trajectory (not illustrated). In this case, advantageously, but without limitation, the control assembly 21 is configured also to operate the further support structure 22' so as to simultaneously deburr/trim the borders 2 and 2', with evident advantages in terms of time and production volume. In particular, advantageously, but without limitation, in this case (that is, when the further abrasive tool 20' is present), the control assembly 21 comprises two control units (not illustrated) each intended to control (namely, operate) one abrasive tool 20 or 20'.

According to other advantageous, but non-limiting, embodiments, in this case (that is, when the further abrasive tool 20' is present), the manufacturing system 1 of articles made of compacted ceramic powder MCP comprises a further control assembly (not illustrated and substantially similar to the control assembly 21) connected at least to the detection assembly 24 and to the deburring/trimming assembly 19 and configured to operate the abrasive tool 20'.

More in detail, advantageously, but without limitation, the manufacturing system 1 of articles made of compacted ceramic powder MCP comprises at least one detection assembly 24 which is arranged and configured to detect at least one quantity correlated with the development of at least the border 2 (to be treated, in particular of at least one of the two transverse borders 2 and 2') of each article made of compacted ceramic powder MCP (and/or of each group G of articles) which, in use, moves on the conveyor assembly 7, in particular on the roller conveyor 15, and the control assembly 21 is connected to the detection assembly 24 and to the deburring/trimming assembly 19 and is configured to operate the deburring/trimming assembly 19 depending on the information detected by the detection assembly 24 so that the deburring/trimming trajectory T (along which the abrasive tool 20 is moved to deburr/trim the border 2) coincides with the development of the border 2.

According to some advantageous, but non-limiting, embodiments of the present invention, the detection assembly 24 is arranged at the detection station 17 arranged downstream of the cutting station 8 along the given path P and, advantageously, but without limitation, upstream of the deburring/trimming station 16 along this given path P. Alternatively, advantageously, but without limitation, the detection assembly 24 is connected (namely, fixed) to the abrasive tool 20 (and/or) to the further abrasive tool 20'. Advantageously, but without limitation, the detection assembly 24 is configured to detect the position of at least two distinct points of at least an upper or lower edge 13 or 13' of this border 2. In this case, advantageously, the control assembly 21 comprises at least one memory (known per se and not illustrated and not described herein) to receive and store setting data comprising at least the thickness of the layer of compacted ceramic powder KP (which the manufacturing system 1 of articles made of compacted ceramic powder MCP is intended to form) and is configured to determine a development of the border 2 depending on the information detected by the detection assembly 24 and on the setting data and to operate the deburring/trimming assembly 19 based on the development determined and on the setting data so that the deburring/trimming trajectory T (along which the abrasive tool 20 is moved to deburr/trim the border 2) coincides with the development of the border 2.

According to some advantageous, but non-limiting, embodiments of the present invention, the detection assembly 24 comprises (in particular, is made up of) at least one video camera 25, (advantageously but without limitation) arranged above the conveyor assembly 7, in particular above the roller conveyor 15, for example at a height with respect to the conveyor assembly 7 (in particular to the roller conveyor 15), such as to detect the position of the aforesaid two points of an upper or lower edge 13 or 13' of the border 2.

According to some non-limiting embodiments, the detection assembly 24 is also configured to detect the position of at least two distinct points of an upper or lower edge 13 or 13' of the further transverse border 2', opposite the transverse border 2, of each of the articles made of compacted ceramic powder MCP (and/or of each group G of articles) and the control assembly 21 is configured to determine the development also of the further border 2', opposite the border 2. In this case, advantageously, but without limitation, the detection assembly 24 comprises (in particular, is made up of) two video cameras 25 (advantageously, but without limitation) placed above the conveyor assembly 7 and mutually arranged so that one video camera 25 detects a quantity correlated with the development (in particular, the position of two points of an upper or lower edge 13 or 13') of the border 2 and the other video camera 25 detects a quantity correlated with the development (in particular, the position of two points of an upper or lower edge 13, 13') of the further border 2 ’ .

According to other embodiments, the detection assembly 24 is configured to detect the development of the entire border 2, 2 ’ which, in use, moves on the conveyor assembly 7, in particular on the roller conveyor 15, for example by means of one or more video cameras and/or by means of other viewing systems (known per se and not further described herein). Alternatively, the detection assembly 24 could be configured to detect the whole lateral profile of each article made of compacted ceramic powder MCP (and/or of each group G of articles) which, in use, moves on the conveyor assembly 7, in particular on the roller conveyor 15, for example by means of one or more video cameras and/or by means of other viewing systems (known per se and not further described herein). Also in this case, advantageously, the control assembly 21 comprises at least one memory (known per se and not illustrated and not described herein) to receive and store setting data comprising at least the thickness of the layer of compacted ceramic powder KP (which the manufacturing system 1 of articles made of compacted ceramic powder MCP is intended to form) and/or the format of the articles made of compacted ceramic powder MCP (which the manufacturing system 1 of articles made of compacted ceramic powder MCP is intended to form) and is configured to determine a development of the border 2 depending on the information detected by the detection assembly 24 and on the setting data.

Thanks to the presence of at least one detection assembly 24 the deburring/trimming assembly 19, advantageously, but not necessarily, in use, follows the real development of the border 2 or 2 to be treated, which allows a more precise finishing (namely, deburring or trimming) of the borders 2 or 2 regardless of the inclination with which the articles made of compacted ceramic powder MCP (and/or the groups G of articles) reach the deburring/trimming station 16, without the need to first rotate or handle the articles made of compacted ceramic powder MCP or the groups G of articles.

Moreover, in order to further improve the efficacy and the precision of the finishing (in particular, deburring/trimming) operations, advantageously, but without limitation (as illustrated schematically in Fig. 6), the deburring/trimming assembly 19 comprises at least one force detection device 26 arranged and configured to continuously detect a contact pressure transmitted, in use, by the abrasive tool 20 (and optionally, when provided, by the further abrasive tool 20') to the border 2 or 2' that is being finished; and the control assembly 21 is configured to adjust the deburring/trimming assembly 19, based on this contact pressure so that the contact pressure transmitted, in use, by the abrasive tool 20 (and optionally, when provided, by the further abrasive tool 20') to the border 2 or 2’ that is being finished remains substantially constant along the entire deburring/trimming trajectory T.

According to some advantageous, but non-limiting, embodiments, the force detection device 26 is arranged on the abrasive tool 20 (and optionally, when provided, on the further abrasive tool 20'), as illustrated schematically in Fig. 6. Alternatively or in addition, the force detection device 26 could be arranged on the support structure 22 (and optionally, when provided, on the further support structure 22') that carries the abrasive tool 20 (and optionally 20'). Advantageously, but without limitation, the force detection device 26 comprises (in particular, is made up of) at least one force sensor of a known type and not further described herein.

With particular reference to Figs. 2 to 6 and 4A, according to some advantageous, but non-limiting, embodiments, the (in particular, each) support structure 22 (and 22') of the deburring/trimming assembly 19 comprises (in particular, is made up of) an anthropomorphic robot 27 (and 21’) of collaborative type (of a known type and not further described herein) . In this case, advantageously, the abrasive tool 20 (in particular also the further abrasive tool 20') can be moved in the space with greater freedom. Moreover, this solution also allows maintenance operations to be carried out on the abrasive tool 20 (in particular also on the further abrasive tool 20'), for example operations to replace one or more grinders, in a simpler manner, thanks to the presence of the robot 27 (and 21’) which allows the abrasive tool 20 (in particular, also the further abrasive tool 20') to be moved out of the footprint of the conveyor assembly 7, when maintenance operations must be carried out, without the need to block the rest of the processing operations.

Advantageously but without limitation (with particular reference to Figs. 2 to 6), the anthropomorphic robot 27 or 21’ is fixed to a horizontal supporting wall 28 (as illustrated partially and schematically in Fig. 6).

Even more in detail, according to some advantageous, but non limiting, embodiments, the manufacturing system 1 comprises a protective structure (not illustrated) which surrounds at least part of the manufacturing system 1 of articles made of compacted ceramic powder MCP and this supporting wall 28 is advantageously, but not necessarily, part of (that is, is comprised in) this protective structure.

Alternatively, according to other embodiments such as the one illustrated schematically in Fig. 7), the (in particular, each) support structure 22 {22’) of the deburring/trimming assembly 19 comprises (in particular, is made up of) at least one linear guide 29 arranged above the conveyor assembly 7, in particular the roller conveyor 15 at the deburring/trimming station 16 and extends substantially crosswise to the moving direction A, and at least a second linear guide 30 which is mounted so as to be movable along the linear guide 29 and extends substantially parallel to the moving direction A. In this case, the abrasive tool 20 (in particular also the further abrasive tool 20') is connected to the linear guide 30 in a sliding manner.

Advantageously, but without limitation, in this case each support structure 22, 22' (in particular, the first linear guide 29) is vertically movable. Even more in detail, advantageously, but without limitation, the control assembly 21 is configured to move each support structure 22, 22' (in particular, the first linear guide 29) up to a height that depends on the thickness of the articles made of compacted ceramic powder MCP, as stated above (therefore on the quantity of ceramic powder CP that is supplied by the supply assembly 3 and/or on the compaction pressure applied by the compaction device 5) so as to guarantee the correct positioning of the abrasive tool 20 or 20' at the border 2 and/or 2 .

According to other non-limiting variants, each support structure 22, 22' could comprise a manual adjustment system to adjust the height of each support structure 22, 22' (in particular, of the first linear guide 29), so as to guarantee the correct positioning of the abrasive tool 20 or 20' at the border 2 and/or at the further border 2 .

According to some advantageous, but non-limiting, embodiments (such as those illustrated in Figs. 3, 4, 4A and 5), particularly advantageous when the articles made of compacted ceramic powder MCP move in groups G of articles, the manufacturing system 1 of articles made of compacted ceramic powder MCP further comprises an aligning assembly 31, which is arranged upstream of the deburring/trimming station 16 along the given path P, in particular along the section PB, and can be operated so as to strike against each group G of articles moving, in use, along the given path P, in particular along the section PB, and align the articles made of compacted ceramic powder MCP of each group G of articles with one another at least along the cross direction B.

In detail, according to some advantageous, but non-limiting, embodiments (such as those illustrated in Figs. 3, 4 and 5), the aligning assembly 31 comprises at least one wall 32 which extends along (namely, parallel to) the cross direction B and is movable between a rest position, in which (advantageously, but without limitation) it does not interfere with the articles made of compacted ceramic powder MCP or with the groups G of articles that, in use, move on the conveyor assembly 7 (for example is above or below the conveyor assembly 7), and an operating position, in which it is arranged to strike against each group G of articles moving, in use, along the given path P and align the articles made of compacted ceramic powder MCP of each group G of articles at least along said cross direction B.

In detail, advantageously, but without limitation, when the conveyor assembly 7 is provided with the roller conveyor 15, this wall 32 is advantageously, but without limitation, arranged between two adjacent rollers 18 of said roller conveyor 15, and is movable between a rest position, in which it lies below or above the rollers 18 so as not to interfere with the articles made of compacted ceramic powder MCP or with the groups G of articles moving, in use, on the conveyor assembly 7, in particular on the roller conveyor 15, and an operating position, in which it projects from the rollers 18 to strike against each of the articles made of compacted ceramic powder MCP, or group G of articles, moving, in use, along the given path P, in particular along the section PB, and align the articles made of compacted ceramic powder MCP of each group G of articles at least along the cross direction B. Alternatively or in combination, according to some embodiments (such as the one illustrated schematically in Fig. 4A), particularly advantageous when the conveyor assembly 7 is provided with the roller conveyor 15, the aligning assembly 31 comprises at least one belt 32 which is (advantageously, but without limitation) arranged between two adjacent rollers 18 of the roller conveyor 15 and is movable between a rest position, in which it does not interfere with the articles made of compacted ceramic powder MCP or the groups G of articles moving, in use, on the conveyor assembly 7, in particular on the roller conveyor 15, for example lies below the rollers 18, and an operating position, in which it projects from the rollers 18 to strike against each group G of articles moving, in use, along the given path P, in particular along the section PB, and align the articles made of compacted ceramic powder MCP of each group G of articles at least along the cross direction B.

Alternatively or in combination, according to some advantageous, but non-limiting, embodiments (such as those illustrated in Figs. 3, 4 and 5), the aligning assembly 31 (also) comprises at least one further wall 33 which extends along the moving direction A and is movable between a rest position, in which it is arranged on one side of the conveyor assembly 7, in particular of the roller conveyor 15, so as not to interfere with the articles made of compacted ceramic powder MCP moving, in use, on the conveyor assembly 7, in particular on the roller conveyor 15, and an operating position, in which it lies above the rollers 18 and, advantageously cooperates with the wall 32 (if provided) or with the belt 32 (if provided), to strike against and align the articles made of compacted ceramic powder MCP of the group G of articles with one another. According to an alternative embodiment, not illustrated, in addition to the wall 33, the aligning assembly 31 could also comprise a further wall which extends along the moving direction A and is movable between a rest position, in which it is arranged on a further side of the conveyor assembly 7, in particular of the roller conveyor 15, opposite with respect to the side of the conveyor assembly 7 outside which the wall 33 lies in the rest position so as not to interfere with the articles made of compacted ceramic powder MCP moving, in use, on the conveyor assembly 7 (in particular, on the roller conveyor 15) and an operating position, in which this further wall lies above the rollers 18 and cooperates with the wall 33 and/or with the wall 32 (if provided) or with the belt 32 (if provided) to strike against and align the articles made of compacted ceramic powder MCP of the group G of articles with one another.

According to a non-limiting embodiment (such as the one illustrated schematically in Fig. 1), the manufacturing system 1 of articles made of compacted ceramic powder MCP also comprises a further deburring/ trimming assembly 35, advantageously arranged at a further deburring/trimming station 36, advantageously, but without limitation, downstream of the trimming station 16 along the given path P, in particular along the section PB of the given path P, and configured to finish the longitudinal borders 2’', 2’’’ of each article made of compacted ceramic powder MCP (and/or of each group G of articles) . Advantageously, but without limitation, this further deburring/trimming assembly 35 (known per se and therefore not described in detail) comprises two linear guides which extend at the sides of the conveyor assembly 7, in particular at the sides of the roller conveyor 15, parallel to the moving direction A and at least two further abrasive tools (advantageously of the type described above with reference to the deburring/trimming assembly 19 and) which can be operated by a further control assembly 37, which advantageously, but without limitation, coincides with the control assembly 21, to intercept and deburr/trim the longitudinal borders 2’’ and 2’'.

According to some advantageous, but non-limiting, embodiments, the manufacturing system 1 of articles made of compacted ceramic powder MCP also comprises at least one suction assembly (of a known type, not illustrated or described herein) configured to suck up the waste material that is produced during finishing (in particular, deburring/trimming) of the articles made of compacted ceramic powder MCP. In detail, advantageously, but without limitation, the suction assembly is arranged above and/or below the conveyor assembly 7, at least at the deburring/trimming station 16 to suck up at least the waste produced during the finishing/deburring/trimming operations.

Alternatively, or in addition, advantageously, but without limitation, the suction assembly comprises at least one suction device 38 (represented schematically in Fig. 6 and) connected to the deburring/trimming assembly 19, in particular to the support structure 22 or 22' or as illustrated schematically in Fig. 6 to the abrasive tool 20 or 20' to directly suck up the waste produced by the abrasive tool 20 or 20' during finishing.

According to a further aspect of the present invention, a method for manufacturing articles made of compacted ceramic powder (of the type described above with reference to the manufacturing system 1 of articles made of compacted ceramic powder MCP) is proposed.

The method comprises: a compaction step, during which the ceramic powder CP is compacted by a compaction device 5 arranged at a compaction station 6, said compaction device 5 (advantageously, but without limitation, of the type described above) applies a compaction pressure to the uncompacted ceramic powder CP so as to obtain a layer of compacted ceramic powder KP; and a conveying step, during which a conveyor assembly 7 (advantageously, but without limitation, of the type described above) conveys the powder material CP along the given path P in the moving direction A, in particular along a section PA of the given path P, from an input station 4 (where this uncompacted ceramic powder CP is supplied by a supply assembly 3 of the type described above) to the aforesaid compaction station 6, and the layer of compacted ceramic powder KP from the compaction station 6 to a (in particular, exiting from a) cutting station 8.

Advantageously, but without limitation, the method also comprises a cutting step, during which a cutting device 12 (advantageously, but without limitation, of the type described above), arranged at the cutting station 8, cuts, at least crosswise, that is, at least parallel to the cross direction B, the layer of compacted ceramic powder KP in order to obtain a plurality of articles made of compacted ceramic powder MCP. According to some advantageous, but non-limiting, embodiments, during the cutting step the cutting device 12 cuts the layer of compacted ceramic powder KP also parallel to the moving direction A so as to obtain groups G of articles, each comprising (in particular, made up of) at least two articles made of compacted ceramic powder MCP at least partially arranged next to one another along the direction B (as illustrated schematically in Figs. 3, 4, 4A and 5).

In other words, as already explained above in relation to the manufacturing system 1 of articles made of compacted ceramic powder MCP, advantageously, but not necessarily, during the cutting step the cutting device 12 can create different formats of articles made of compacted ceramic powder MCP each provided with at least two transverse borders 2, 2', that is, that develop substantially crosswise to the moving direction A, and two longitudinal borders 2’’ and 2’'', that is, that develop substantially along the moving direction A. Each of these borders 2, 2', 2’’ and 2’’’ is advantageously provided with an upper edge 13 and with a lower edge 13'.

Advantageously, but without limitation, the conveying step provides for a moving sub-step, during which the articles made of compacted ceramic powder MCP (optionally organized in groups G of articles) are moved, by the conveyor assembly 7 (advantageously by the above-described roller conveyor 15) along the given path P, in particular along a section PB of the given path P, said section PB developing downstream of the section PA, as better explained above with reference to the manufacturing system 1 of articles made of compacted ceramic powder MCP .

Advantageously, but without limitation, the method also comprises a finishing (in particular, deburring/trimming) step, during which a deburring/trimming assembly 19, arranged at a deburring/trimming station 16, finishes (in particular, deburrs/trims) at least one border 2 transverse to the moving direction A of each article made of compacted ceramic powder MCP.

Advantageously, but without limitation (as illustrated in the accompanying figures), the deburring/trimming station 16 is located downstream of the cutting station 8 along the given path P, in particular along the section PB of the given path

P.

Advantageously, but without limitation, the deburring/trimming assembly 19 comprises at least one abrasive tool 20 to trim/deburr the border 2 and one support structure 22 which carries the abrasive tool 20 and can be operated, advantageously, by a control assembly 21, to move the abrasive tool 20 along a deburring/trimming trajectory T (illustrated schematically in Fig. 6). Even more in detail, advantageously, but without limitation, the deburring/trimming assembly 19 is of the type described above with reference to the manufacturing system 1 of articles made of compacted ceramic powder MCP .

According to some advantageous, but non-limiting, embodiments, the finishing step is carried out statically, that is, by stopping the articles made of compacted ceramic powder MCP, or the group G of articles, for the time necessary to finish (in particular, deburr/trim) the border 2 of each article made of compacted ceramic powder MCP. According to other non-limiting embodiments (and particularly advantageous when during the finishing step, the deburring/trimming assembly 19 finishes (in particular, deburrs/trims) only the upper edges 13 of the border 2 or 2 of each article made of compacted ceramic powder MCP), the finishing step is simultaneous with the moving sub-step.

Advantageously, but without limitation, the articles made of compacted ceramic powder MCP move along the conveyor assembly 7, and in particular are moved into the deburring/trimming station 16 spaced from one another by a given distance value, so that an article made of compacted ceramic powder MCP or a group G of articles reaches the deburring/trimming station 16 as soon as another exits from the same deburring/trimming station 16. In particular, advantageously, but without limitation, the given distance value is at least equal to around 15cm, in particular is at least equal to around 20cm. Advantageously, but without limitation, the method for manufacturing articles made of compacted ceramic powder MCP further comprises a first detection step, at least partially simultaneous with the moving sub-step and at least partially prior to the finishing step, during which at least one detection assembly 24 (advantageously, but without limitation, produced according to one of the embodiments described above) detects a quantity correlated with the development of the aforesaid border 2; and an operating step, at least partially subsequent to the first detection step and at least partially simultaneous with the finishing step, during which the control assembly 21 operates the deburring/trimming assembly 19 depending on the information detected by the detection assembly 24. Alternatively, or in combination, according to some advantageous, but non-limiting, embodiments, the first detection step is at least partially simultaneous with the finishing step.

According to some advantageous, but non-limiting, embodiments, the method comprises a setting step, during which setting data is provided, which comprises at least the thickness of the layer of compacted ceramic powder KP. In this case, advantageously, during the first detection step the detection assembly 24 detects a position of at least two points of an upper or lower edge 13 or 13' of the border 2; and during the control step the control assembly 21 determines a development of the border 2, depending on the information detected by the detection assembly 24 and on the setting data, and operates the deburring/trimming assembly 19 so that the deburring/trimming trajectory T coincides with this determined development of the border 2.

Similarly to what was indicated above in relation to the manufacturing system 1 of articles made of compacted ceramic powder MCP, advantageously, but without limitation, during the detection step the detection assembly 24 also detects a quantity correlated with the development of a further transverse border 2’ of each article made of compacted ceramic powder MCP (or group of articles made of compacted ceramic powder), opposite the border 2 (in particular, detects the position of two distinct points of an upper or lower edge 13 or 13' of this further border 2'), and during the finishing step the deburring/trimming assembly 19 also finishes this further border 2’ ; advantageously, in this case, the deburring/trimming assembly 19 finishes both the borders 2 and 2’ simultaneously.

In this case, advantageously, but without limitation, the detection assembly 24 can comprise two video cameras 25 (as explained above in relation to the manufacturing system 1 of articles made of compacted ceramic powder MCP ), one video camera 25 which detects the aforesaid quantity correlated to the development, in particular, the position of two distinct points of an upper or lower edge 13 or 13') of the border 2 and the other video camera 25 which detects, advantageously simultaneously, a quantity correlated to the development (in particular, the position of two distinct points of an upper or lower edge 13 or 13') of the border 2’.

Advantageously, but not necessarily, the deburring/trimming assembly 19 also comprises a further abrasive tool 20' and a further support structure 22', which carries the further abrasive tool 20' and can be operated to move it along a further deburring/trimming trajectory (not illustrated). Advantageously, but without limitation, the method also comprises a second detection step, at least partially simultaneous with the finishing step, during which one force detection device 26 (advantageously of the type described above) continuously detects a contact pressure transmitted, in use, by the abrasive tool 20 to the border 2 (in particular, by each abrasive tool 20, 20' to the border 2 or 2’ which it finishes/deburrs/trims ); and an adjustment step, during which the control assembly 21 adjusts the deburring/trimming assembly 19, based on the contact pressure detected so that the contact pressure transmitted, in use, by the abrasive tool 20 (in particular, by each abrasive tool 20, 20') to the border 2 (in particular, also to each border 2, 2') remains substantially constant along the entire deburring/trimming trajectory T (in particular, also along the further trajectory) .

Alternatively, as stated above in relation to the manufacturing system 1 of articles made of compacted ceramic powder MCP, according to some non-limiting embodiments, during the detection step the detection assembly 24 detects the development of the entire border 2 and/or 2’ of each article made of compacted ceramic powder MCP (and/or of each group G of articles) which, in use, moves on the conveyor assembly 7, in particular on the roller conveyor 15, for example by means of one or more video cameras and/or by means of other viewing systems (known per se and not further described herein). Alternatively, the detection assembly 24 detects the entire lateral profile of each article made of compacted ceramic powder MCP (and/or of each group G of articles) which, in use, moves on the conveyor assembly 7, in particular on the roller conveyor 15, for example by means of one or more video cameras and/or by means of other viewing systems (known per se and not further described herein).

According to some non-limiting embodiments (such as those illustrated in Figs. 3, 4, 4A and 5), particularly advantageous when the articles made of compacted ceramic powder MCP are moved in groups G of articles, the method for manufacturing articles made of compacted ceramic powder MCP also comprises an aligning step, at least partially prior to the finishing step, during which an aligning assembly 31 strikes against each group G of articles moving, in use, along the given path P, in particular along the section PB, and aligns the articles made of compacted ceramic powder MCP of each group G of articles at least along the cross direction B. Advantageously, but without limitation, this aligning step is implemented by an aligning assembly 31 produced according to any one of the embodiments described above.

Advantageously, but without limitation, the method also comprises a further finishing step, during which a further deburring/trimming assembly 35, advantageously arranged at a further deburring/trimming station 36 arranged downstream of the trimming station 16 along the section PB of the given path P, finishes/deburrs the longitudinal borders 2’', 2’’’ of each article made of compacted ceramic powder MCP (or of each group G of articles) which in use moves at this deburring/trimming station 36.

According to some advantageous, but non-limiting, embodiments, the method also comprises a suction step at least partially simultaneous with the finishing step, during which a suction assembly (of a known type, not illustrated or described herein, which advantageously, but without limitation, comprises the suction device 38 described above and illustrated schematically in Fig. 6) sucks up the waste material produced during finishing of the articles made of compacted ceramic powder MCP (or of each group G of articles). The method and the manufacturing system 1 for forming articles made of compacted ceramic powder MCP of the present invention has numerous advantages, among which the following are cited. Firstly, the method and the manufacturing system 1 for forming articles made of compacted ceramic powder MCP of the invention allow more precise finishing (namely, deburring/trimming) of all the transverse borders 2, 2 of the articles made of compacted ceramic powder MCP thanks to the presence of the detection assembly 24 and to the feedback operation of the deburring/trimming assembly 19 which, in this manner, will follow the actual development of the border 2 or 2 to be treated. This guarantees a more precise and repeatable action of the abrasive tool 20 or 20' along the entire border 2 or 2 to be treated regardless of the inclination with which each article made of compacted ceramic powder MCP reaches the deburring/trimming station 16 and/or of the imperfections or of the format of the articles made of compacted ceramic powder MCP to be finished.

Furthermore, the method and the manufacturing system 1 for forming articles made of compacted ceramic powder MCP of the invention allow the transverse borders 2 and 2 of each article made of compacted ceramic powder MCP to be treated more rapidly with respect to known methods and systems, thanks to the particular type of support structure 21 or 21' which carries each abrasive tool 20 or 20'. In particular, it has been surprisingly observed that the time required for the treatment of each border 2, 2 with the method and the manufacturing system 1 described above reaches values in the order of a couple of seconds. Furthermore, thanks to the presence of a deburring/trimming assembly 19 which can be easily mounted directly in the line, the manufacturing system 1 described above has a much smaller footprint with respect to known systems. This allows the manufacturing system 1 and the method for manufacturing articles made of compacted ceramic powder of the invention to be used also in the most modern manufacturing plants of ceramic products, which reach production speeds of up to 40/70 workpieces per minute.