PROCESSING MODULE FOR A BUILDING PANEL

Abstract

The present invention relates to a processing module for a building panel and a method for processing a building panel. The processing module for a building panel comprises an input station and a manoeuvring station. The input station comprises a reception for a building panel and the building panel bundles several individual building elements. The manoeuvring station comprises a swiveling device for transporting and swiveling the building panel.

Claims

1. A processing module for a building panel, comprising: an input station, and a manoeuvring station, wherein the input station comprises a reception for a building panel, wherein the building panel bundles a plurality of individual building elements, and wherein the manoeuvring station comprises a swiveling device for transporting and swiveling the building panel.

2. The processing module of claim 1, further comprising a sawing device with a cutting wire for separating the individual components from the building panel.

3. The processing module of claim 2, wherein the sawing device comprises a drive coil and a counter coil, wherein the drive spool is adapted to wind the cutting wire in a first direction, and wherein the counter spool is configured for tensioning the cutting wire in an opposite, second direction.

4. The processing module of claim 2, wherein the drive spool and the counter spool are configured to cyclically change their tasks so that the cutting wire is wound alternately in the first direction and the second direction for cutting.

5. The processing module of claim 2, wherein only between 1 and 10%, preferably between 1 and 5% of a total length of the cutting wire is used for a current cutting operation.

6. The processing module of claim 3, further comprising a control unit adapted to control at least one of the spools for a constant wire tension of the cutting wire during a cutting operation.

7. The processing module of claim 3, further comprising a speed sensor for detecting an instantaneous cutting speed of the cutting wire, wherein the speed sensor is preferably arranged on a deflection roller of the sawing device.

8. The processing module of claim 3, further comprising a speed sensor for detecting an instantaneous spool speed of the counter spool.

9. The processing module of claim 6, wherein the control unit is configured to calculate an instantaneous total spool diameter of the counter spool together with the instantaneous spool rotational speed of the counter spool from the instantaneous cutting speed of the cutting wire and the instantaneous spool rotational speed of the counter spool.

10. The processing module of claim 6, wherein the control unit is further configured to continuously calculate from the instantaneous total spool diameter of the counter spool a desired driving torque of the counter spool for a constant wire tension and/or a constant cutting speed of the cutting wire during a cutting operation.

11. The processing module of claim 3, wherein at least one of the spools is configured to maintain a defined wire tension of the cutting wire also in a rest state of the sawing device.

12. The processing module of claim 2, wherein the sawing device is a wire saw with a hard material wire.

13. The processing module of claim 3, further comprising a pendulum device for the drive spool and/or the counter spool, which is configured to move the drive spool and/or the counter spool up and down substantially perpendicular to a cutting direction of the cutting wire.

14. The processing module of claim 13, wherein the pendulum device is configured to control the movement of the drive spool and/or the counter spool depending on an instantaneous cutting speed of the cutting wire.

15. The processing module of claim 13, wherein the pendulum device is configured to move the drive spool and/or the counter spool independently of each other so that different cutting angles can be set.

16. The processing module of claim 2, further comprising a wear monitoring device, which is configured to measure a cutting force of the cutting wire during a cutting operation and to output an indication of an actual wear of the cutting wire on the basis of the measured cutting force.

17. The processing module of claim 3, further comprising a wire breakage monitoring device which is configured to measure a spool speed of the drive spool and/or a spool rotation time of the counter spool and to output a statement on a possible wire breakage on the basis of the measured spool speed.

18. The processing module of claim 1, further comprising a granular bath which can be acted upon by compressed gas for receiving and fixing the individual components relative to the building panel, wherein the granular bath is in a quasi-solid state in a rest state and is in a quasi-liquid state when acted upon by compressed gas.

19. A method for processing a building panel, comprising: providing a processing module and a manoeuvring station, inserting a building panel into a reception of the input station, the building panel bundling a plurality of individual building elements, and transporting and/or swiveling the building panel by means of a swiveling device in the manoeuvring station.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0099] FIG. 1 shows a processing module for a building panel according to an embodiment of the invention.

[0100] FIG. 2 shows a detailed view of a sawing device for cutting individual components from the building panel.

[0101] FIG. 3 shows a top view of the sawing device for cutting individual components from the building panel.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0102] FIG. 1 shows a processing module 1 for a building panel 2 with an input station 10 and a manoeuvring station 20. The input station 10 comprises a reception 11 for a building panel 2. The manoeuvring station 20 comprises a swiveling device 21 for transporting and swiveling the building panel 2.

[0103] The building panel 2 bundles several individual components 3. The building panel 2 can have a plate-shaped basic structure from which the individual components 3 protrude in the form of pins or fingers. The individual components 3, which are later separated, can be understood as the actual products to be manufactured.

[0104] The processing module 1 comprises a granulate bath 30, which can be pressurized with compressed gas, for reception and fixing of the individual components 3 relative to the building panel 2. The granulate bath 30 is in a quasi-solid state when at rest and in a quasi-liquid state when pressurized gas is applied. The granulate bath 30 is located in a component collecting container 31. The component collecting container is lifted relative to building panel 2 with the individual components 3 by means of the swiveling device 21 so that the individual components 3 are immersed in the granulate bath 30 at building panel 2. The granulate bath 30, which can be perceived as solid, is flushed with compressed gas during the immersion of the components 3 so that it assumes a state which can be perceived as liquid and in which the components 3 can be immersed without major frictional losses. Subsequently, the individual components 3 arranged on the building panel 2 are immersed in the component collection container 31 or the quasi liquid granulate. The compressed gas is switched off when the components 3 are at least partially or preferably completely immersed in the granulate. Without the compressed gas purging, the granulate solidifies to such an extent that the components 3 are sufficiently fixed in the granulate so that they are not displaced or entrained by the shear forces in a subsequent separation process. The granulate bath 30 is described in more detail below.

[0105] The individual components 3 are then separated from the building panel 2 using a sawing device 40. The processing module 1 therefore also includes the sawing device 40 with a cutting wire 41 for separating the individual components 3 from the building panel 2. The sawing device 40 is a diamond wire saw in which the cutting wire 41 is guided parallel to the surface of the building panel 2. The sawing device 40 on is explained in more detail below with reference to FIGS. 2 and 3.

[0106] After the components 3 have been separated from building panel 2, the building panel 2 is reprocessed by moving an overhead building panel reprocessing station relative to building panel 2. The reprocessing is a mechanical processing of building panel 2 by, for example, milling, grinding, polishing and similar. The panel reprocessing station is described in more detail below.

[0107] The process in the processing module 1 can be as follows: [0108] Inserting a building panel 2 into a building container 12. [0109] Positioning the building container 12 on a reception 11 or a table 11 in the input station 10 using a mobile transport aid. [0110] Moving the table 11 with building container 12 from the input station 10 to the manoeuvring station 20 by means of a mandrel 13 with a building panel clamping system. [0111] Gripping and lifting the building container 12 from the table 11 by means of a swiveling device 21. [0112] Moving the table 11 (without the building container) from the manoeuvring station 20 back to the input station 10. The mandrel 13 with a clamping system is now exposed. [0113] Lowering the building container 12 onto the mandrel 13 and the clamping system using the swiveling device 21. The mandrel 13 can be approached inside the building container 12 right up to the underside of the building panel 2. An optional base plate can be placed between the mandrel and the underside of the panel-shaped base structure of building panel 2. [0114] Fix the building panel 2 or the optional base plate, if necessary using a clamping system, to the mandrel 13 and the clamping system through an opening in the bottom of building container 12. [0115] Lowering of building container 12 relative to building panel 2 and/or raising of building panel 2 relative to building container 12 by means of the swiveling device 21. During the relative movement between building panel 2 and building container 12, building panel 2 is moved to a raised position inside building container 12 by the mandrel 13. [0116] Release the swiveling device 21 from the building container 12. [0117] If necessary, release building panel 2 from the optional base plate. [0118] Grip the building panel 2 using the swiveling device 21. [0119] Lifting the building panel 2 using the swiveling device 21. [0120] Moving the table 11 from the input station 10 back to the manoeuvring station 20 and under the building panel 2 using the mandrel 13 and the clamping system. Table 11 is used to cover the mandrel 13 and the clamping system to protect against dust or powder residues. [0121] Swivel the building panel 2 using the swiveling device 21 so that the building panel 2 faces an adapter plate 22 and the individual components 3 face away from the adapter plate 22. The building panel 2 is lifted so far that it can be swiveled or rotated above the table 11. The swiveling can be a swiveling by 180. The swiveling device 21 moves the building panel 2 under the adapter plate 22. [0122] Fasten the building panel 2 to the adapter plate 22 using a fixing system. The fixing is sufficiently strong to allow the individual components 3 to be separated from building panel 2 in the following and to allow building panel recycling. [0123] Detaching the swiveling device 21 from the building panel 2. [0124] Moving a tray 32 with a component collecting container 31 under the building panel 2, wherein the component collecting container 31 comprises a granulate bath 30. The tray 32 is a second linearly movable table 32. [0125] Gripping and lifting the component collecting container 31 by means of the swiveling device 21 so that the individual components 3 on the building panel 2 are immersed in the granulate bath 30, the granulate bath 30 being acted upon by compressed gas and being in a quasi-liquid state. [0126] stopping the pressurized gas flushing of the granulate bath 30 so that the granulate bath 30 comes into a quasi-solid state and the individual components 3 are fixed in the granulate bath 30 so as not to be displaced by shear forces in a subsequent separation process. [0127] Separation of the individual components 3 from the building panel 2 using a sawing device 40, which is explained in more detail below with reference to FIGS. 2 and 3. [0128] Lowering of the component collection container 31 using the swiveling device 21. The component collection container 31 contains the individual components 3 that have just been separated. [0129] Lowering the component collecting container 31 onto the tray 32 (second linearly movable table). [0130] Moving the tray 32 with the component collecting container 31 from the maneuvering station 20 to a starting station 33. [0131] Output of the component collection container 32 with the individual components 3 from the output station 33 using the mobile transport means. [0132] Moving a building panel recycling station mounted upside down relative to and here under the building panel 2 attached to the adapter plate 22. [0133] Mechanical processing (milling, grinding, polishing or similar) of building panel 2 with the aid of the building panel reprocessing station. [0134] Gripping the building panel 2 using the swiveling device 21. [0135] Detaching the building panel 2 from the adapter plate 22. [0136] Swivel (here 180) and transport the building panel 2 back into the building container 12 using the swiveling device 21. [0137] Detach the swiveling device 21 from the building panel 2. [0138] Gripping the building container 12 by means of the swiveling device 21. The swiveling device 21 grips the building container 12 with the fixed building panel 2 and lifts the building container 12 so far that the first linearly movable table 11 can be moved under the building container 12. [0139] Positioning of the building container 12 on the first linearly movable table 11 by means of the swiveling device 21. [0140] Moving the table 11 with the building container and building panel 2 from the manoeuvring station 20 back to the input station 10.

[0141] FIGS. 2 and 3 show detailed views of the sawing device 40 for cutting the individual components 3 from the building panel 2. The sawing device 40 here is a diamond wire saw, the cutting wire 41 here is a hard coated wire.

[0142] The sawing device 40 comprises a drive spool 42 and a counter spool 43. The drive spool 42 is designed to wind the cutting wire 41 in a first direction. The counter spool 43 is designed to tension the cutting wire 41 in an opposite, second direction.

[0143] The sawing device 40 works by winding and unwinding the cutting wire 41. The cutting wire 41 can be several kilometers long. During the sawing process, however, the cutting wire 41 is not wound up and unwound in its full length, but only a certain section of wire, which can only be a few hundred meters long. Preferably only between 1 and 10% of the total length of the cutting wire 41 is used for a current cutting operation, further preferably between 1 and 5% of the total length of the cutting wire 41.

[0144] The cutting wire 41 is wound onto the drive spool 42 in the first direction of movement (here clockwise) with a torque M.sub.2. The winding axis of the drive spool 42 determines the angular velocity or spool speed n.sub.2. The counter spool 43, which is designed to unwind the cutting wire 41 in the second, opposite direction of movement (here counter-clockwise), produces a defined counter-torque M.sub.1 at an angular speed or spool speed n.sub.1. The cutting speed v of the cutting wire 41 can be measured by a speed control with feedback signal of the wire speed at a deflection roller 45 provided with a speed sensor 44 and, if desired, kept constant. The cutting speed is freely adjustable, even during a cutting operation.

[0145] The counter-torque M.sub.1 of the counter spool 43 is permanently controlled to ensure a constant wire tension .sub.S in the cutting wire 41. The counter torque M.sub.1 of the counter spool 43 necessary for the constant wire tension .sub.S in the cutting wire 41 can be calculated from the current total spool diameter of the unwinding counter spool 43 together with the currently wound cutting wire 41. The current total spool diameter of the counter spool 43 together with the currently wound cutting wire 41 can be calculated from the current wire speed and the current spool speed n.sub.1 of the counter spool 43. The current wire speed or cutting speed v of the cutting wire 41 can be determined by a speed sensor 44 or encoder in a deflection pulley 45; 49. The actual spool speed n.sub.1 of the counter spool 43 can be determined by a speed sensor 46 or encoder in the counter spool 43. .sub.C is the resulting tension from the cutting force.

[0146] Processing module 1 comprises a control unit (not shown) which calculates the instantaneous total spool diameter of the counter spool 43 together with the instantaneous wound cutting wire 41 from the instantaneous cutting speed of the cutting wire 41 and the instantaneous spool speed n.sub.1 of the counter spool 43. Furthermore, the control unit continuously calculates a desired drive torque of the counter spool 43 for a constant wire tension of the cutting wire 41 during a cutting process from the current total spool diameter of the drive spool 42. In other words, the control unit uses the calculated driving torque of the counter spool 43 to control a constant wire tension of the cutting wire 41 during a cutting operation. The control unit can also use the calculated driving torque of the counter spool 43 to control a constant cutting speed v of the cutting wire 41 during a cutting operation.

[0147] The control unit can further control at least the counter spool 43 in such a way that the wire tension .sub.S of the cutting wire 41 remains constant permanently and thus also in the stationary state of the sawing device 40 and/or when changing the cutting direction. A change of the cutting direction means that the spool that was previously winding unwinds and the spool that was previously unwinding winds up. The drive spool 42 and the counter spool 43 are designed to change their tasks so that the cutting wire 41 can be wound alternately in the first direction and the second direction for cutting.

[0148] In order to wind and unwind the cutting wire 41 as orderly and wear-free as possible, the drive spool 42 and the counter spool 43 can be moved up and down against each other. For this purpose, processing module 1 comprises a pendulum device for the drive spool 42 and the counter spool 43, which is designed to move the drive spool 42 and the counter spool 43 up and down perpendicular to the cutting direction of the cutting wire 41. The pendulum device can control the pendulum movement of the drive spool 42 and the counter spool 43 in dependence on an instantaneous cutting speed v of the cutting wire 41. The pendulum device can also move the drive spool 42 and the counter spool 43 independently of each other, so that different cutting angles are possible.

[0149] Processing module 1 also includes a wear monitoring device that measures a cutting force of the cutting wire 41 during a cutting process and can output a statement on the current wear of the cutting wire 41 based on the measured cutting force. An increasing cutting force can be used to derive an increasing wire wear. From a certain wire wear, a previously unused wire section can be used. This can be repeated until all wire sections are engaged. The cutting wire 41 is thus subject to sectional wear.

[0150] Processing module 1 also includes a wire breakage monitoring device which measures a spool speed of the drive spool 42 and/or a spool rotation time of the counter spool 43 and can give an indication of a possible wire breakage on the basis of the measured spool speed. In this way, the speeds of preferably both spools are observed during cutting or sawing, whereby a possible wire break can be detected immediately.

[0151] The drive spool 42 and the counter spool 43 can each be arranged in a separate sawing unit 47. The two sawing units 47 can be linearly displaced independently of each other. With the aid of inductive sensors 48, for example, the displacement of the sawing units can be controlled so that different cutting angles are possible. In addition, the sensors 48 help to avoid too large or critical cutting angles. Furthermore, the sensors 48 can be used to detect whether or not the component has been cut.

[0152] In addition, it should be noted that comprising and having does not exclude other elements or steps. It should also be noted that features or steps described with reference to one of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference signs in the claims are not to be considered as a restriction.