MACHINE TOOL FOR PROCESSING SAW DISKS

Abstract

The present invention is part of machine tools that today are widely used in all mechanical workshops, often being designed and built also to perform very specific tasks.

In particular, the present invention relates to the processing of discs for circular saws or saw-disks.

Claims

1. A machine device tool for processing saw disks or a semi-finished tool saw disk, the machine device tool comprising: at least one processor; a spindle unit having at least one shank provided with a flange to mount the semi-finished tool saw disk to planarized; at least one sensor assembly having at least one sensor mounted on a carriage to slide at least from the periphery of said disk to the centre of said disk, said sensor detecting the differences in planarity in at least each part of a disk face and communicating said data to said processor; at least one hammer assembly having at least one beating head or hammer; at least one preloading spring for giving said beating head the thrust for striking areas of discrepancy detected by at least said sensor, said thrust, or said processing being determined by said processor and regulator.

2. The machine device tool according to claim 1, wherein said carriage (11) giving said sensor (10) a translatory movement in the radial direction of the disk (5) and said disk rotating around its central axis, this allowing the complete scanning of at least one side of the disk (5).

3. The machine device tool according to claim 2, wherein at least two sensors (10) are configured to measure on each face of the disk such that the disk (5) is rotated for measurement on the first and second faces.

4. The machine device (1) tool according to claim 1, wherein said hammer (13) includes at least one beating bolt (300) and at least one additional anvil bolt (301) to act as a stop for the beating bolt, the disk (5) to be machined being placed between pads (302) mounted on pneumatic cylinders (303) to avoid resonance of the disk after the blow are further included.

5. The machine device tool according to claim 1, wherein said sensor (10) is a capacitive sensor.

6. The machine device tool according to claim 1 further comprising a loading/unloading system, comprising at least a support, a handgrip, a handwheel, to said support being fixed solidly blade supports to support the disk to be mounted and also the handle and the handwheel being fixed therein in a solid manner, said system being able to position the disk on the spindle unit to perform the positioning and/or the semiautomatic discharge of even the disks that are heavy.

7. A method for processing saw disks using a machine device tool, the machine device tool having: at least one processor; a spindle unit having at least one shank provided with a flange to mount the semi-finished tool saw disk to planarized; at least one sensor assembly having at least one sensor mounted on a carriage to slide at least from the periphery of said disk to the centre of said disk, said sensor detecting the differences in planarity in at least each part of a disk face and communicating said data to said processor; at least one hammer assembly having at least one beating head or hammer; at least one preloading spring for giving said beating head the thrust for striking areas of discrepancy detected by at least said sensor, said thrust, or said processing being determined by said processor and regulator, the method comprising: retaining, via the processor, the data collected by said sensor; controlling, via the processor, the thrust for the work carried out; detecting, via the processor, data by means of these sensors after the machining operations are carried out; storing and processing, via the processor, correction parameters for future machining with substantially identical data to speed up operations; wherein said processor is adapted to perform self-learning.

8. The method according to claim 7, further comprising: collecting, via the sensor data concerning the surface of the disk; processing the data collected by the sensor; in case of discrepancy: processing by means of the processor of the correction to be performed; performing the correction by means of a command to the beating head; verification of the result obtained by means of a sensor; if the correction falls within the tolerance range, end of processing, disk discharge; if the correction is outside the data tolerance range; detecting, via the sensor, discrepancies; repeating operations until the result is obtained; end of processing, disk discharge.

9. The machine device tool according to claim 2, wherein at least two sensors (10) are configured to measure on each face of the disk such that the sensors move on the other face of the disk for greater detection accuracy.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0044] These and other advantages will be obtained by virtue of the innovative machine tool for the processing of saw disks described in this invention as better explained below with reference to the description of the figures representing some embodiment forms of the present invention, in which:

[0045] in FIG. 1 it is represented a preferred embodiment form of the innovative machine tool;

[0046] in FIG. 2 it is represented a preferred embodiment form of a particular of the sensor assembly of said machine tool;

[0047] in FIG. 3 it is represented a preferred embodiment form of a part of the spindle assembly;

[0048] in FIG. 4 it is represented a preferred embodiment form of a detail of the hammer group;

[0049] in FIG. 5 it is represented a preferred embodiment form of a particular of the disk loading/unloading group (which may or may not be present depending on the preferred embodiment forms).

DETAILED DESCRIPTION OF THE FIGURES

[0050] In FIG. 1 it is represented a preferred form of realization of the innovative machine tool 1 for the planarization of toothed disks and saw disks 5.

[0051] In this particular representation, a workpiece/disk 5 is already mounted on the machine tool 1. Said workpiece 5 or disk, is mounted on a spindle unit 2 by means of a quick coupling by means of a shank 16 which will be described in more detail in the following figures.

[0052] It should be noted that only the parts that are functionally useful to describe the innovative features of the present invention will be described in detail below, being intended that the skilled person has full knowledge of the functioning of generic machine tools already known on the market. In particular, a tensioning unit 12, in this case for example provided with rollers, will be used to compact the steel of the disk giving it a structural rib that will make it more stable through a compression applied between the two faces of the disk to be machined.

[0053] Also included are: at least one hammer assembly 3, one sensor assembly 4, one computer and regulator assembly 6, one vertical carriage assembly 7, and one additional transverse carriage assembly 8.

[0054] After the first pretensioning phase, once spindle 2 is started, disk 5 begins to rotate by means of spindle 2, the disk having an axis of rotation coinciding with that of said spindle. Sensor assembly 4 can perform a translatory movement in the direction of the spindle rotation axis and allows a capacitive sensor (visible in FIG. 2) mounted, for example, at an end of sensor assembly 4, to move from the periphery of disk 5, namely the external circumference of the disk, to the part closest to the attachment shank 16, namely to the centre of the disk being machined 5.

[0055] The composition of degrees of freedom, namely the rotation of disk 5 and the movement of the sensor with translatory movement along the surface of disk 5, will make it possible to analyze the entire surface of the disk itself: the capacitive sensor will detect point by point (with a resolution that can be defined a priori by the computer and regulator 6) data regarding the areas out of tolerance of planarity, in particular regarding the surface of the area out of tolerance and the thickness or degree of relief with respect to the plane (if such roughnesses exist). The spatial coordinates of these areas are identified, for example, by measuring at least two coordinates, such as for example, an angular coordinate of the spindle axis and a straight coordinate relative to the displacement of the sensor according to a straight coordinate relative to the displacement of the carriage on which the sensor 10 is mounted, these coordinates form a part of the data.

[0056] The data sent in the first place are: those collected by the sensor in relation to the position of the deformation and its degree of relevance will be transmitted continuously to a computer and regulator 6 able to record not only the deformations before processing but also the changes that occurred after the “hammering” carried out in order to recover the tolerance: so there will be data sent to the computer 6 also whenever it is performed a “correction” operation on the disk, to control the result.

[0057] The computer 6 will then command the hammer assembly 3, (which will be further described in a later figure), by sending data relating to the thrust parameters that must be applied on the impact mass (namely to the head of the hammer, by a spring) in order to hit the zone or area out of tolerance detected with the force indicated by the computer 6.

[0058] Once the area or areas subject to deformation have been identified, hammer assembly 3 will position itself with its active part, namely the hammering head, close to that area, exerting one or more percussions depending on the degree of tolerance to be corrected. Hammer assembly 3 will be able to work the entire surface of the disk by virtue of the rotation of disk 5 on the axis of the spindle and by virtue of the displacement of hammer assembly 3 in the vertical direction made by a vertical carriage 7 and a transverse displacement made by a transverse carriage 8.

[0059] The computer 6, therefore, in a completely innovative and advantageous way, will provide to maintain both an archive of the processing carried out and will also use this archive for a subsequent self-regulation of the processing parameters based on the results previously obtained. In essence, the computer and regulator 6 can also perform functions of self-adaptive control, this in a completely innovative and advantageous way, also excluding in this phase of processing totally the presence of staff who could do the same job based only on their experience and with certainly greater times (and risks). This operation becomes therefore repeatable and industrially reproducible in a simple and effective way.

[0060] In FIG. 2 it is represented the detail of the sensor assembly 4 in which it is highlighted the sensor part or sensor 10 for example of capacitive type: by virtue of the movement of the carriage 11 composed of a moving part that slides in a guide, this sensor can move from the periphery of the disk 5 to the innermost part of the disk itself.

[0061] The moving part is driven, for example, by an electric motor. The sensor 10 can examine the whole surface of disk 5 thanks also to the rotation of said disk. Said capacitive sensor 10, will detect the discrepancies present on both faces of the disk, in fact the defects of planarity being detectable substantially indistinctly from one or the other face usually as said to a hump on one face corresponds a depression on the other face, at least for the most common defects.

[0062] In particular, by detecting planarity and/or out-of-tolerance defects, this referring to the plane identified by the disk clamping flange, which will be described below. As described above, these data are sent to the computer and regulator 6.

[0063] Note that, in one or more embodiment variants, at least two sensors can be present, one for measurement on each face of the disk, or the disk can be rotated for measurement on the other face, or the sensor can be rotated, this for greater accuracy.

[0064] FIG. 3 shows the part of spindle assembly 2 in which the head of the spindle 9 on which the disk will be mounted is highlighted for the processing phase on the innovative machine tool. The spindle will be equipped with a quick coupling in which to insert a shank for tightening the disk to be machined.

[0065] The shank (not visible here) can be fixed to the spindle, for example, by means of a ball coupling controlled by a pneumatic piston 25, able to hold the shank in its seat 10 in the spindle head 9. The head of the spindle 9 will rotate the disk 5 both for a first phase of planarity analysis, and for a second phase of actual processing, which will be carried out by means of the hammer that will correct the areas out of tolerance and/or excessively deformed. The figure shows the structural elements that support the spindle head and the motor for its drive. Obvious technical details are not specified and are merely construction details.

[0066] FIG. 4 shows the detail of the hammer assembly 3 which is connected to the transversal carriage 8 and which includes as substantial elements at least a hammer 13 and a spring 15 with a preload piston 14 (not visible here). The preload piston, depending on the amount of force to be used to correct a certain degree of defect detected by sensor 10 on the surface of disk 5, will load the spring 15 which will then transfer the elastic energy at the time of the blow, to the beating head. As said, innovatively, the force with which to preload the spring, will be determined to time by time autonomously by the computer and regulator 6 that, based upon learning on the previously processed cases, will determine independently how to best dose this force in order to obtain the desired effect.

[0067] A detail of hammer assembly 3 is visible in FIG. 4a where in particular it is represented the hammer head 13 that comprises at least one beating bolt 300 and at least one additional anvil bolt 301 to act as a stop for the beating bolt. Among them is obviously placed the disk to be worked on. There are also pads 302, for example made of rubber, mounted on pneumatic cylinders 303 which avoid the resonance of the disk after the blow. To eliminate friction between the beating head 13 and its housing 130, compressed air is injected (by means of a solenoid valve or a suitable medium) in this housing to form an air cushion, thus avoiding the sliding of the head into the housing and the consequent wear and tear.

[0068] FIGS. 5a and 5b show a variant of a preferred form of design of a system 80 for loading and unloading the disk on/from the machine, in order to facilitate the positioning of large disks. This system can be optionally present on the machine tool object of the invention. With the increase of the diameter and consequent thickness of the blades, it becomes physically difficult and demanding the unloading but above all the loading of the blades.

[0069] With more detailed reference to FIG. 5b, where it is represented a disk 5 mounted on the machine, the machine comprising said loading/unloading system 80.

[0070] System 80 includes at least a support 21, a handgrip 19, a handwheel 18, to said structural support 21 are fixed solidly a plurality of blade supports 17 to support the disk to be mounted and there are also fixed solidly said handgrip and said handwheel, this to perform positioning and/or unloading in a semiautomatic way even for the heaviest disks.

[0071] To operate the system 80, proceed as follows: the handgrip 19 is grasped and the system 80 is dragged until the end of the stroke (towards the operator), a handwheel 18 is rotated to adjust the blade supports 17 in relation to the diameter of the blade/disk 5 that will be mounted (a numeric indicator is further included in which it is expressed in mm corresponding to the diameter of the blade to be loaded). By regulating the blade supports 17, by consequence, the central hole of the disk, once loaded on these supports, is in correspondence with the connection of the shank 16 on the spindle, this therefore advantageously avoids that such loading is carried out manually by an operator with the difficulties of keeping a heavy disk in balance when fixing it in the spindle.

[0072] The 80 system further includes a part of the frame 30 connected to the support 21, by means of a hinge that allows the rotation of the support 21 with respect to the frame 30 of a small angle, this rotation is made by exerting a force on the handgrip 19, favoring the insertion of the shank 16 in the spindle and then the fixing of the blade on the spindle, the blade is substantially pushed on the spindle, the supports accordingly are axially and radially distance from the teeth of the blade allowing it to rotate and release from the supports 17.

[0073] It is evident that the present invention allows to solve all the described problems of prior art allowing to obtain all the described advantages, noting that variants in materials used for the machine, materials in which the disks are made, size and weight of the same, variants in the type of sensors for measurements, in the mode of assembly parts, provided that they achieve the purposes of this invention, means of automation, type of carriages, etc. are all considered variants of the embodiment this invention and therefore fall within the scope of protection of this invention as better described by the annexed claims.