Compaction system and method for replacing belt of compaction system

Abstract

The invention relates to a compaction system and a method for replacing a belt of a compaction system. A compaction system (1) comprises: a main frame (3); a compaction device (2) which in turn comprises a conveying surface (5) and a belt-type compaction element (6) defining a compaction surface (9) facing the conveying surface (5), and a pressing assembly (10) for bringing the compaction surface (9) and the conveying surface (5) closer to each other; and a positioning device (18) configured to carry the belt compaction element (6) above the conveying surface (5) such that a gap (17) is defined between the belt compaction element (6) and the conveying surface (5), and the positioning device (18) comprises a fixed side plate (19), a movable plate (20) and a locking system (21) interposed between the main frame (3) and the movable plate (20) to releasably connect the movable plate (20) to the main frame (3).

Description

[0001] Cross - reference to related applications

[0002] This patent application claims the priority of Italian Patent Application No. 102023000028284, filed on December 28, 2023, the entire disclosure of which is incorporated herein by reference. Technical field

[0003] The present invention relates to a compaction system and method for compacting ceramic powders; more specifically, to a compaction system and method for compacting a layer of powder material comprising ceramic powders. Background art

[0004] In the ceramic processing industry, tile forming devices are known, which include a flexible conveyor belt on which ceramic powders are gradually deposited.

[0005] The powder layer is conveyed by a conveying surface through successive compaction stations, where the powder layer is compacted as it is conveyed on the conveying surface.

[0006] Compaction devices typically include two flexible compaction surfaces, one above the other, and the two surfaces are capable of sliding in the same direction.

[0007] Each compaction surface is typically defined by a corresponding flexible sliding belt, which is usually made of steel and wound around at least two rollers, a motor - driven roller, and pulleys.

[0008] The lower compaction surface is typically arranged to be in direct contact with the conveying surface to support the conveying surface or to coincide with the conveying surface; while the upper compaction surface is arranged parallel to the conveying surface and at a given distance (i.e., height) above the conveying surface, such that a gap is defined between them, which is designed to receive the powder material layer to be compacted.

[0009] The upper compaction surface acts directly on the powder layer passing thereunder, compacting the powder layer. Specifically, in a predetermined area, the compaction surface is guided by special pressing means (e.g., a pair of pressing rollers stacked one on top of the other), which keep the upper compaction surface locally pressed against the lower compaction surface to press the powder layer.

[0010] Downstream of the compaction station, the conveying surface finally conveys the compacted powder layer through successive processing stations, such as subsequent cutting stations, where the strip of compacted powder is divided into individual plates or tiles.

[0011] Although this type of compaction system provides excellent performance, it has some drawbacks, which are mainly related to maintenance operations that can be quite complex.

[0012] Specifically, one of the main problems with these solutions relates to the need to periodically replace the flexible belt that constitutes the upper compaction surface.

[0013] This replacement operation is particularly complex and requires first disassembling the roller system around which the belt is wound to loosen the belt so that it can be removed from the roller on which it is assembled, and then repositioning the new belt. Due to the weight and size of the parts to be moved, these operations are very complex, time-consuming, and require the intervention of skilled workers.

[0014] To attempt to simplify these operations, some compaction systems of the applicant have been known for years and provide a main frame and positioning means, the main frame defining a housing for receiving the compaction device, the positioning means being constructed to support the upper compaction surface and to enable the flexible belt included therein to be easily replaced.

[0015] Specifically, the known compaction systems include: a lower, generally belt-shaped conveying surface, which is supported by the main frame and is designed to convey the powder layer to be compacted and serves as the lower compaction surface; a motor-driven roller and pulley, which are rotatably supported by the main frame and around which the flexible belt is assembled, the flexible belt serving as the upper pressing surface; two opposite side accommodation guides, which are carried by the positioning means to accommodate the ceramic powder layer on the sides; and two pressing rollers, one pressing roller cooperating with the lower pressing surface and the other pressing roller cooperating with the upper pressing surface. In use, the pressing rollers act on the upper pressing surface to bring it closer to the lower pressing surface, thereby compacting the powder layer conveyed on the conveying surface between these pressing surfaces.

[0016] The positioning means includes: fixed side plates for supporting a plurality of upper rollers at a given distance from the lower pressing surface; an upper support; and a movable side plate hinged to the main frame. The upper support supports two side accommodation elements, which are hinged to the fixed side plates and releasably attached to the movable side plate to hold it in the closed position. During the operation for replacing the flexible belt, the movable plate is released from the upper support so that the movable plate can rotate relative to the main frame and the upper support can rotate relative to the fixed side plates, thereby releasing the space used by the operator to remove and / or insert the flexible belt.

[0017] However, although this solution is effective, it also has drawbacks.

[0018] In fact, the above-mentioned positioning device is very troublesome, and even after the movable plate and the upper bracket are opened, the space that the operator can operate in is limited. Therefore, the disassembly and replacement of the flexible belt require highly skilled operators. The operator must be able to enter this limited space, lift the pressing roller in order to release the pressure on the belt wound around the upper roller and remove the belt without disturbing the main frame and / or the upper bracket that define this operating space even in the rotating position at the top.

[0019] In addition, the above-mentioned positioning device is very troublesome and limits the accessible area of the compaction device, making the maintenance operations experienced by other components of the machine more complex.

[0020] In addition, the production of ceramic products inherently involves the generation of dust, making it a problem in this industry to use machines with exposed frames (such as the upper bracket of the positioning device) that represent potential locations where dust may accumulate. In fact, such dust accumulation may cause problems in the case of uncontrolled falling of the accumulated dust; for example, in such a case, if the dust accumulated on the upper bracket of the positioning device of a known machine falls due to any reason (vibration, air, etc.), they may dirty the pressing belt or ultimately on the powder layer to be compacted, or even worse, on the already compacted powder layer, thereby damaging the final quality of the final product. Summary of the Invention

[0021] According to the present invention, there is provided a compaction system and a method for replacing the pressing belt of the compaction system according to the appended independent claims and preferably according to any dependent claim directly or indirectly subordinate to the foregoing independent claims.

[0022] The appended claims describe the preferred embodiments of the present invention and form part of the description. Brief Description of the Drawings

[0023] The present invention will now be described with reference to the drawings showing some non-limiting embodiments of the present invention, wherein:

[0024] - Figure 1 is a perspective view of a compaction system according to an embodiment of the present invention;

[0025] - Figure 2 shows a view similar to Figure 1 where some parts are omitted to make other parts visible;

[0026] - Figure 3 and Figure 4 are Figure 1 two side views of the compaction system shown in

[0027] - Figure 5 shows Figure 4Cross-sectional view of the compaction system shown along plane V-V;

[0028] - Figure 6 shows Figure 3 Cross-sectional view of the compaction system shown along plane VI-VI;

[0029] - Figure 7A and Figure 7B are Figure 1 Two side views of greater scale of detail W to better show the connection between the fixed frame and the movable side wall of the compaction system of the present invention;

[0030] - Figure 7C and Figure 7D Are two side views of greater scale of another possible embodiment of the connection between the fixed frame and the movable side wall of the compaction system according to the present invention;

[0031] - Figure 8 Is a perspective view of the compaction system of Figure 1 during the replacement of the upper flexible belt;

[0032] - Figure 9 Shows a view similar to Figure 8 where some parts are omitted to make other parts visible;

[0033] - Figure 10 and Figure 11 are Figure 9 Two side views of the compaction system shown;

[0034] - Figure 12 Shows Figure 10 Cross-sectional view of the compaction system shown along plane XIII-XIII; and

[0035] - Figure 13 Shows Figure 11 Cross-sectional view of the compaction system shown along plane XIV-XIV. Detailed Description

[0036] In the drawings, the numeral 1 generally denotes a compaction system for compacting a layer of powder material (not visible in the drawings) comprising ceramic powder. More precisely, the powder material is ceramic powder. In particular, the compaction system 1 can be used in an apparatus for forming ceramic tiles or plates.

[0037] It should be noted that in this specification, words such as "upper", "lower", "side", "right", "left" or "height" are used with reference to the compaction system 1 resting on a horizontal plane (e.g., resting on the ground or a floor) (e.g., as Figures 1 to 13as shown, such that terms like "at the top" or "at the bottom" respectively refer to being "above" or "below", or "farther from" or "closer to" the horizontal plane on which the compaction system 1 is rested (thus "farther from" or "closer to" the floor or ground) relative to another component of the compaction system 1 when the compaction system 1 is rested on the floor or the ground. Similarly, "inside" and "outside" mean "inside" and "outside" of the compaction system 1. Further, for the present invention, the term "second" component does not imply the existence of a "first" component. In fact, these terms are only used as labels to enhance clarity and should not be construed in a limiting manner.

[0038] The compaction system 1 shown in the accompanying drawings advantageously includes a compaction device 2 and a main frame 3. The main frame 3 is advantageously fixed and, even more advantageously but not in a limiting way, defines a housing 4 for receiving the compaction device 2.

[0039] The compaction device 2 includes: a lower conveying surface 5 supported by the main frame 3 and configured to convey a layer of powder material along a conveying path P in a conveying direction A; a belt compaction element 6 which in turn includes a plurality of rollers 7a, 7b having horizontal axes and a pressing belt 8. Among the plurality of rollers 7a, 7b there is (in particular, includes) a motor-driven roller 7a and a pulley 7b (or a tension roller), and the pressing belt 8 is wound around the plurality of rollers 7a, 7b to define an upper compaction surface 9 facing the conveying surface 5 by means of its lower branch; and a pressing assembly 10 arranged in the region of a compaction station 11 provided along the path P and configured to bring the upper compaction surface 9 and the conveying surface 5 closer to each other so as to compress the layer of powder material conveyed therebetween during use.

[0040] According to some advantageous but non-limiting embodiments, such as the embodiment shown in the accompanying drawings, the compaction device 2 includes an additional belt compaction element 12 which in turn includes an additional plurality of rollers 13 having horizontal axes and an additional belt 14 wound around the plurality of rollers 13. Among the additional plurality of rollers 13 there is (in particular, includes) at least one motor-driven roller 13 and one or more idler rollers 13 (in the case shown herein, one idler roller 13), and the additional belt 14 is configured to define an additional lower compaction surface 15 located below the conveying surface 5 by means of its upper branch. Even more advantageously but not in a limiting way, the compaction surface 15 is in direct contact with the conveying surface 5.

[0041] Advantageously, but not by way of limitation, the lower compaction surface 15 is advantageously operated by the aforementioned motor-driven roller 13 so as to slide in the same conveying direction A as the conveying surface 5 and substantially at the same speed as the conveying surface 5, thereby avoiding relative scratching. According to some advantageous but non-limiting embodiments, such as the embodiments shown in the figures, the lower compaction surface 15 coincides with the conveying surface 5; even more advantageously, but not by way of limitation, it defines (in particular, constitutes) the conveying surface 5 along at least a section of the conveying path P.

[0042] In this case (i.e., when the compaction system 1 includes an additional belt compaction element 12), advantageously, but not by way of limitation, two pressing belts 8, 14 are provided one above the other in the region of the compaction station 11, namely the lower pressing belt 14 and the upper pressing belt 8.

[0043] Advantageously, but not by way of limitation, the upper pressing belt 8 is made of a metallic material (such as steel). Alternatively or additionally, advantageously, but not by way of limitation, the upper pressing belt 8 is made of a plastic material.

[0044] Furthermore, when there is a lower pressing belt 14, the lower pressing belt 14 is also advantageously but not by way of limitation made of a metallic material (such as steel) or a plastic material.

[0045] In use, the powder material layer is advantageously but not by way of limitation conveyed continuously by the conveying surface 5 through the compaction station 11, where the powder material layer is compacted due to the action of the pressing assembly 10 as the powder material layer is conveyed in the conveying direction A.

[0046] Advantageously, but not by way of limitation, the pressing assembly 10 is configured to locally hold the upper compaction surface 9 pressed against the conveying surface 5 so as to compress the powder material layer therebetween.

[0047] According to some advantageous but non-limiting embodiments, such as the embodiments shown in the figures, the pressing assembly 10 includes a pair of pressing rollers 16a, 16b having horizontal and rotation axes orthogonal to the conveying direction A and arranged one above the other, namely the lower pressing roller 16a located below the conveying surface 5 and configured to (in particular, arranged at a certain height so as to) maintain the flatness of the conveying surface 5 and the upper pressing roller 16b operatively coupled to the belt compaction element 6.

[0048] Advantageously, but not by way of limitation, the pressing rollers 16a, 16b are movable relative to each other to vary the extent (in particular, the thickness) of the gap 17 defined between the conveying surface 5 and the compaction surface 9 in the region of the compaction station 11 (for example, see Figure 2 、 Figure 9), so as to compact the layer of powder material conveyed between them during use. More particularly, the pressing rollers 16a, 16b can move relative to each other to bring the conveying surface 5 (more particularly, the lower compaction surface 15) and the upper compaction surface 9 closer to each other.

[0049] According to some advantageous but non - limiting embodiments, such as those shown in the figures, the lower pressing roller 16a is fixed, and the upper pressing roller 16b is connected to at least one jack (not visible in the figures) or another moving system, which is capable of changing the height of the upper pressing roller 16b (i.e., the distance from the lower pressing roller 16a) and / or the applied force, for example, according to the thickness of the layer of powder material to be compacted and / or the compaction pressure to be applied to said layer.

[0050] According to some advantageous but non - limiting embodiments, such as those shown in the figures, the upper pressing roller 16b is interposed between the motor - driven roller 7a and the idler pulley 7b that are in contact with the pressing belt 8 (particularly, in contact with the inner face of the pressing belt 8), and the lower pressing roller 16a is in direct contact with the conveying surface 5 (more particularly, when there is the additional belt - type compaction element 12 as described above, it is in contact with the lower pressing belt 14).

[0051] Advantageously, the compaction device 2 according to the present invention further includes a positioning device 18, which is configured to carry the belt - type compaction element 6 so as to define the above - mentioned gap 17 for the layer of powder material to pass between the belt - type compaction element 6 and the conveying surface 5. Advantageously, but not in a limiting way, the positioning device 18 is arranged inside the housing 4 and is adapted to maintain the position of the belt - type compaction element 6 relative to the conveying surface 5 (particularly, relative to the lower belt - type compaction element 12 when there is one).

[0052] With particular reference to the figures, the positioning device 18 advantageously includes: a fixed side plate 19, which is connected (particularly, integrally) to the fixed main frame 3 on the first side L1 of the compaction device 2 and is configured to rotatably support a plurality of rollers 7a, 7b of the belt - type compaction element 6 at a given distance from the conveying surface 5, so as to define the aforementioned gap 17 therebetween, the size of which is set to allow the layer of powder material to be compacted to pass through.

[0053] In addition, according to some advantageous but non - limiting embodiments, such as Figures 1 to 13In the illustrated embodiment, the positioning device 18 further includes: a movable plate 20, which is arranged on the second side L2 of the compaction device 2 parallel and opposite to the first side L1 and is rotationally coupled to the main frame 3; and a locking system 21, which is interposed between the main frame 3 and the movable plate 20 on the second side L2 and is configured to releasably connect the movable plate 20 to the main frame 3 (in particular, to integrate them).

[0054] Advantageously, but not by way of limitation, the positioning device 18 is capable of transitioning between a first operating configuration and a second configuration, and vice versa (i.e., from the second configuration to the aforementioned first configuration). In the first operating configuration, the locking system 21 connects the movable plate 20 (in particular, exclusively the movable plate 20) to the main frame 3 to laterally define a part of the compaction device 2 (in particular, to laterally define at least a part of the aforementioned gap 17). In the second configuration, the locking system 21 is released and the movable plate 20 rotates relative to the main frame 3 to make the part of the gap 17 accessible and to define a manipulation space allowing the replacement of the upper pressing belt 8. More advantageously, but not by way of limitation, in the first configuration, the locking system 21 exclusively connects (i.e., without inserting other components) the movable plate 20 to the fixed main frame 3.

[0055] According to some advantageous but non-limiting embodiments, the main frame 3 includes a lower support part 22 and an upper support part 23. The lower support part 22 is arranged on the second side L2 of the compaction device 2, and the upper support part 23 is arranged on the second side L2 of the compaction device 2, above the lower support part 22 and at a distance from the lower support part 22 in a direction B perpendicular to the conveying surface 5, and this distance is at least equal to the extension (in particular, the thickness) of the gap 17. The upper support part 23 is configured to rotatably support a plurality of rollers 7a, 7b on the second side L2 of the compaction device 1. In this case, advantageously, but not by way of limitation, the locking system 21 is interposed between the upper support part 23 and the movable plate 20 so as to releasably connect the movable plate 20 exclusively to the fixed main frame 3, and more particularly, to the upper support part 23.

[0056] Advantageously, but not by way of limitation, with particular reference to Figure 7A 、 Figure 7B 、 Figure 7C 、 Figure 7D ,the movable plate 20 and the upper support part 23 are mutually configured to be side by side in the region of at least one coupling zone Z, and the locking system 21 is arranged in the region of the coupling zone. More advantageously, but not by way of limitation, in this case, the movable plate 20 and the upper support part 23 can be side by side in a direction parallel to the conveying direction A (see Figure 7A andFigure 7B ) or side by side perpendicular to the conveying direction A and the conveying surface 5 (see Figure 7C and Figure 7D ).

[0057] According to some advantageous but non - limiting embodiments, the locking system 21 is configured to form a shape coupling between the movable plate 20 and the main frame 3; in particular, a shape coupling is formed between the movable plate 20 and the upper support portion 23.

[0058] According to some advantageous but non - limiting embodiments, for example Figure 7A , Figure 7B , Figure 7C and Figure 7D the embodiments shown, the locking system 21 includes: a first coupling element 24, which is integral with the movable plate 20 and movable between a retracted position and a withdrawn position; a further coupling element (not visible in the drawings), which is integral with the upper support portion 23 and configured to receive the first coupling element 24; and an actuator 25 for operating the first coupling element 24 between the withdrawn position and the retracted position such that the positioning device 18 changes from a first configuration to a second configuration (in particular, capable of changing from the first configuration to the second configuration); in particular, such that the locking system 21 is released to disconnect the movable plate 20 from the frame 3, thereby allowing the positioning device 18 to change from the first configuration to the second configuration. According to other embodiments not shown herein, the first coupling element 24 may be integral with the upper support portion 23, and the second coupling element may be integral with the movable plate 20.

[0059] Advantageously, but not in a limiting way, the first coupling element 24 is a pin, and the above - mentioned actuator 25 includes a pneumatic actuator (in particular, consists of a pneumatic actuator).

[0060] Alternatively or additionally, advantageously, but not in a limiting way, the second coupling element includes a seat having a cross - section complementary to that of the first coupling element 24 for receiving and holding the first coupling element 24 in the withdrawn position.

[0061] According to some advantageous but non - limiting embodiments, for example Figure 1 , Figure 7A , Figure 7B , Figure 7C and Figure 7D the embodiments shown, the upper support portion 23 includes a protruding portion 26, and the movable plate 20 includes a hole 27 (more particularly, advantageously, but not in a limiting way, which is U - shaped to define the hole 27), the hole 27 being configured to receive the protruding portion 26, and the locking system 21 being configured to connect the movable plate 20 to the protruding portion 26.

[0062] According to some advantageous but non - limiting embodiments, such as those shown herein, the positioning device 18 includes at least one pneumatically - operated device 30 (in the case shown herein, including two pneumatically - operated devices 30), which can be operated to move the movable plate 20 relative to the main frame 3 (specifically, relative to the upper support portion 23) between a first position when the positioning device 18 is in a first configuration (see Figure 1 , Figure 2 , Figure 4 , Figure 6 ) and a second position when the positioning device 18 is in a second configuration (see Figure 9 , Figure 10 , Figure 12 ). In the first position, the movable plate 20 is substantially parallel to and opposite the side plate 19. In the second position, the movable plate 20 rotates relative to the main frame 3 (specifically, relative to the upper support portion 23) so that the gap 17 is accessible.

[0063] Advantageously, but not by way of limitation, in this second position, the movable plate 20 rotates through an angle from approximately 70° to approximately 120°; more particularly, through an angle of approximately 90°.

[0064] According to some advantageous but non - limiting embodiments, such as those shown in the drawings, the compaction system 1 further includes a lifting assembly 32, which is operatively connected to the belt compaction element 6 and can be operated to act on the inner surface of the pressing belt 8 (specifically, to apply a pushing action) so as to lift the pressing belt 8 relative to the rollers 7a, 7b, 16a (specifically, lift it to the rollers 7a, 7b, 16a), thereby facilitating (more advantageously, but not by way of limitation, achieving) the removal (specifically, the removal) of the pressing belt 8 during the replacement of the pressing belt 8.

[0065] Advantageously, but not by way of limitation (see in particular Figure 2 , Figure 6 , Figure 10 ), the main frame 3 includes: at least one vertical support 33, which is arranged on the first side L1 of the compaction device 2 and bears the side plate 19; and at least one transverse member 34 for connecting the vertical support 33 to the upper support portion 23 and thus connecting the side plate 19 to the upper support portion 23 (possibly, but not by way of limitation, through an auxiliary element also included in the frame 3). More advantageously, but not by way of limitation, the above - mentioned lifting assembly 32 is connected to the transverse member 34 (specifically, it is carried by the transverse member 34).

[0066] In the non - restrictive embodiment shown in the drawings, the main frame 3 includes two vertical supports 33 and a pair of transverse members 34. The two vertical supports 33 are placed at two transverse ends of the side plate 19. The pair of transverse members 34 are configured to connect the vertical supports 33 to the upper support portion 23 and thus connect the side plate 19 to the upper support portion 23.

[0067] Even more advantageously, but not in a limiting way, the lifting assembly 32 includes at least one push bar 35 and at least one operating device 36. The at least one push bar 35 extends transversely to the conveying direction A parallel to the plurality of rollers 7a, 7b, 16a (see Figure 2 , Figure 10 , Figure 13 ). The at least one operating device 36 is configured to move the push bar 35 in a vertical direction B perpendicular to the conveying surface 12 between a first height (advantageously, but not in a limiting way, lower than the height of the pressing belt 8) in a rest position (see Figures 1 to 8 ) and a second height higher than the first height in an operating position (see Figures 8 to 13 ). More particularly, the second height is greater than or equal to the height of the upper end of the main frame 3 on the second side L2 (in particular, at the upper end of the upper support portion 23 of the main frame 3), such that during the replacement of the pressing belt 8, after the pressing belt 8 has been lifted to the second height, it is easier to remove it, in particular to slide it out of the housing 4.

[0068] Even more advantageously, but not in a limiting way, as in the case shown herein, the lifting assembly 32 includes two similar push bars 35 and two similar operating devices 36. The two similar push bars 35 extend transversely to the conveying direction A parallel to the plurality of rollers 7a, 7b, 16a. Each operating device 36 is configured to move one of the push bars 35 in the vertical direction B between the first height and the second height. In this case, advantageously, but not in a limiting way, one of the push bars 35 and the associated operating device 36 are arranged upstream of the pressing assembly 10 along the conveying path P, while the other push bar 35 and the associated operating device 36 are arranged downstream of the pressing assembly 10 along the conveying path P. In other words, in this case, the bars 35 are arranged one on one side and one on the other side of the pressing assembly 10 along the conveying path P.

[0069] According to some advantageous but non - restrictive embodiments, (in particular, each) operating device 36 includes at least one rod 37 and an actuator 38 (in particular, consisting of at least one rod 37 and an actuator 38). The rod 37 extends in the vertical direction B. The actuator 38 can be operated to extend or shorten the rod 37 (e.g., see Figure 9 and Figure 12)。More advantageously, but not in a limiting way, the rod 37 comprises a telescopic rod (in particular, a telescopic rod).

[0070] Alternatively or additionally, advantageously but not in a limiting way, the compaction system 1 comprises an operating assembly 40 which is operatively interposed between the main frame 3 and the upper belt compaction element 6 and which can be operated to move at least one of the rollers 7a, 7b relative to each other, thereby reducing or increasing their mutual distance and thus reducing or increasing the tension of the pressing belt 8.

[0071] More particularly, according to some advantageous but non - limiting embodiments, such as those shown in the drawings, the operating assembly 40 is operatively interposed between the upper support portion 23 and the idler pulley 7b and can be operated to translate the idler pulley 7b relative to the motor - driven roller 7a. In this way, the tension of the pressing belt 8 can be adjusted and, during the replacement of the pressing belt 8, the idler pulley 7b can be moved closer to the motor - driven roller 7a in order to loosen the pressing belt 8 and facilitate its removal (in particular, its extraction).

[0072] Advantageously, but not in a limiting way, the operating assembly 40 comprises at least one pneumatic cylinder 41 which can be operated to move the idler pulley 7b in a translation direction substantially parallel to the conveying direction A towards or away from the motor - driven roller 7a and is operatively connected to the main frame 3 (more particularly, to the upper support portion 23) by means of a guiding system 42 configured to guide the idler pulley 7b during its translation.

[0073] In detail, according to some advantageous but non - limiting embodiments, such as those shown in the drawings, the guiding system 42 comprises a sliding block 43 (in particular, consisting of the sliding block 43) which is connected to one end of the pneumatic cylinder 41 and is provided with a pair of bushings (not visible in the drawings) which are configured to slidably receive a pair of core columns 44 (which are part of the compaction system 1), the pair of core columns 44 being fixed to the main frame 3 (in particular, to the upper support portion 23) and extending in a translation direction substantially parallel to the conveying direction A to guide (i.e., to constrain along a defined translation direction) the translation of the idler pulley 7b. Alternatively, according to other advantageous but non - limiting embodiments not shown herein, the guiding system 42 comprises two guides integral with the main frame 3 (more particularly, integral with the upper support portion 23) for guiding (i.e., to constrain along a defined translation direction) the translation of the idler pulley 7b.

[0074] According to other advantageous but non - limiting embodiments not shown herein, instead of the pneumatic cylinder 41, the operating assembly 40 may comprise any other type of actuator, such as an electric or hydraulic actuator.

[0075] According to some advantageous but non - limiting embodiments, the compaction system 1 includes a pair of side receiving elements (not visible in the drawings) carried by the main frame 3 and opposite each other on the sides of the conveying path P to receive therebetween, in use, a layer of powder material conveyed between the conveying surface 5 and the compaction surface 9. Advantageously, but not by way of limitation, the side receiving elements include partitions (in particular, consisting of partitions supported by the main frame 3).

[0076] According to another aspect of the invention, there is provided a method for replacing the pressing belt 8 of a compaction system 1 advantageously according to one of the above - described embodiments.

[0077] Advantageously, the replacement method includes the following steps: an opening step during which the positioning device 18 (advantageously, but not by way of limitation, the positioning device 18 as described above) is operated to transition from a first configuration to a second configuration; a preparation step during which the pressing belt 8 is loosened; a removal step during which the pressing belt 8 is removed from the compaction device 2; an insertion step during which a new pressing belt 8 is assembled between the plurality of rollers 7a, 7b of the belt - type compaction element 6; and a closing step during which the positioning device 18 is operated to transition from the second configuration to the first configuration.

[0078] Advantageously, but not by way of limitation, the foregoing preparation step includes a moving sub - step during which at least one of the plurality of rollers 7a, 7b of the belt - type compaction element 6 is translated parallel to the conveying direction A so as to loosen the pressing belt 8.

[0079] Advantageously, but not by way of limitation, in this case, during the said moving step, advantageously, but not by way of limitation, as described above with respect to the compaction system 1, the operating assembly 40 interposed between the main frame 3 and the upper belt - type compaction element 6 causes the idler pulley 7b to move in a translation direction parallel to the conveying direction A so as to bring the idler pulley 7b closer to the motor - driven roller 7a, thereby loosening the pressing belt 8 and facilitating its removal (in particular, its extraction).

[0080] Alternatively or additionally, advantageously, but not by way of limitation, the foregoing preparation step includes an additional moving sub - step during which the upper pressing roller 16b is translated in a direction B perpendicular to the conveying surface 5 so as to increase the said gap 17. Advantageously, but not by way of limitation, during this additional moving sub - step, the pressing roller 16b is translated upwards to a height at least equal to the height of the upper end portion of the main frame 3 on the second side L2; in particular, to the height of the upper end portion of the upper support part 23 of the main frame 3.

[0081] Advantageously, but not in a limiting way, when the compaction system 1 includes a lifting assembly 32 advantageously of the above type, the replacement method further includes: a lifting step, which advantageously is at least partially before the removal step, and during which the lifting assembly 32 lifts the pressing belt 8 relative to the plurality of rollers 7a, 7b so as to enable (in particular, facilitate) the removal (in particular, the extraction) of the pressing belt 8; and a lowering step, which advantageously is at least partially after the removal step, and even more advantageously, but not in a limiting way, at least partially before the insertion step and during which the lifting assembly 32 is deactivated.

[0082] According to some advantageous but non - limiting embodiments, the removal step involves: a first sub - step, during which, more advantageously, but not in a limiting way, a truck with forks (not visible in the drawings) is placed beside the compaction system 1 on the aforementioned second side L2 such that at least a part of the truck (even more advantageously, but not in a limiting way, the forks of the truck) is inserted under the lifted pressing belt 8 to receive the pressing belt 8, on which the pressing belt 8 then rests; and a second sub - step, during which the truck moves away from the compaction system 1, i.e., it is translated out of the housing 4.

[0083] Alternatively or additionally, advantageously, but not in a limiting way, the pressing belt 8 is manually translated during the aforementioned removal step so as to disengage from the aforementioned housing.

[0084] According to some advantageous but non - limiting embodiments, the insertion step involves: a first sub - step, during which a new pressing belt 8 is assembled on the aforementioned truck (in particular, inserted so as to rest on it); a second sub - step, during which the truck approaches the compaction system 1 on the aforementioned second side L2 and is translated so as to be inserted into the aforementioned housing 4 to release the new pressing belt 8 in place. More advantageously, but not in a limiting way, the forks of the aforementioned truck have a plurality of upper forks and a plurality of lower forks such that during the aforementioned second sub - step, the plurality of upper forks are inserted above the plurality of rollers 7a, 7b and the plurality of lower forks are inserted below the plurality of rollers 7a, 7b to release the new pressing belt 8 in place.

[0085] Alternatively or additionally, advantageously, but not in a limiting way, during the insertion step, a new pressing belt 8 is manually inserted.

[0086] The compaction system 1 according to the invention and the replacement method for replacing the pressing belt 8 of the compaction system 1 offer a number of advantages, among which the following are worth mentioning.

[0087] The compacting system 1 and replacement method disclosed above enable the operations to be performed for replacing the pressing belt 8 of the upper belt compacting element 6 to be simplified, thus reducing the time required to perform these operations, and thus increasing the efficiency of the compacting system 1, reducing the necessary labor and thus reducing costs.

[0088] Furthermore, by accelerating and simplifying the replacement of the pressing belt 8, the compacting system 1 according to the present invention and the method for replacing the pressing belt 8 of the compacting system 1 are ideal for the use / application of a more flexible production line designed to produce different types of ceramic tiles and plates (e.g., structured products having a specific structure and / or specific decoration on the exposed surface) by more easily and quickly simply replacing the pressing belt 8 each time to adapt it to the need.

[0089] Furthermore, the compacting system 1 of the present invention enables a wider manipulation space for replacing the pressing belt 8 to be formed in the above operation configuration by providing a positioning device 18 that is simpler and less cumbersome than known systems, thereby increasing the freedom of movement of the operator actually performing the replacement of the pressing belt.

[0090] In addition, this configuration of the positioning device 18 (which does not involve the space occupied above the compacting device 2) also facilitates the maintenance operations experienced by other components of the compacting device 2. For example, it facilitates the operator's access to perform maintenance and cleaning operations on the cleaning unit mounted on the compacting device 2 to ensure the cleaning of the pressing belt during its service life.

[0091] Furthermore, the locking system 21 provided herein allows for a reduction in mechanical complexity and a maintenance of the accommodation dimensions while maintaining the same reliability and robustness of the connection.

Claims

1. A compaction system (1) for compacting a powder material layer, the powder material layer comprising ceramic powder; the compaction system (1) comprising: Main frame (3); A compacting device (2), the compacting device (2) comprising: a conveying surface (5), the conveying surface (5) being configured to convey the powder material layer in a conveying direction (A) along a conveying path (P); a belt-type compacting element (6), the belt-type compacting element (6) comprising a plurality of rollers (7a, 7b) having horizontal axes and a pressing belt (8), at least one of the plurality of rollers (7a, 7b) being a motor drive axis (7a), the pressing belt (8) being wound around the plurality of rollers (7a, 7b) so as to define a compacting surface (9) facing the conveying surface (5) by means of its lower branches; and a pressing assembly (10), the pressing assembly (10) being configured to bring the compacting surface (9) and the conveying surface (5) closer to each other so as to compress the powder material layer conveyed between them during use; and A positioning device (18) for driving the belt compacting element (6) so as to leave a gap (17) defined by the passage of the powder material layer between the belt compacting element (6) and the conveying surface (5); the positioning device (18) further comprises: a side plate (19) connected to the main frame (3) on the first side (L1) of the compacting device (2) and configured to support the plurality of rollers (7a, 7b) in a rotatable manner ); a movable plate (20), the movable plate (20) being arranged on a second side (L2) of the compacting device (2) opposite to the first side (L1) and being coupled to the main frame (3) in a rotational manner; and a locking system (21), the locking system (21) being interposed between the main frame (3) and the movable plate (20) on the second side (L2) and being configured to releasably connect the movable plate (20) to the main frame (3); The positioning device (18) is capable of being transformed between a first operating configuration, in which the locking system (21) connects the main frame (3) to the movable plate (20) to laterally define a portion of the compacting device (2) including at least a portion of the gap (17), and a second configuration, in which the locking system (21) is released and the movable plate (20) is rotated relative to the main frame (3) to define a manipulation space allowing the pressing belt (8) to be replaced.

2. The compaction system (1) according to claim 1, wherein: The main frame (3) comprises, on the second side (L2), a first support portion (22) and a second support portion (23), the second support portion (23) being arranged above the first support portion (22) and at a given distance from the support portion (22) in a direction (B) perpendicular to the conveying surface (5), the given distance being at least equal to the extension (particularly, thickness) of the gap (17), and the second support portion (23) being configured to support the plurality of rollers (7a, 7b) in a rotatable manner on the second side (L2) of the compacting device (2); The movable plate (20) is connected to the first supporting portion (22) of the main frame (3) in a rotatable manner; and The locking system (21) is interposed between the second supporting part (23) and the movable plate (20) in order to releasably connect the movable plate (20) to the second supporting part (23).

3. The compaction system (1) according to claim 1, wherein: The positioning device (18) includes a pneumatic operating device (30) which can be operated to move the movable plate (20) relative to the main frame (3) between a first position when the positioning device (18) is in the first configuration and a second position when the positioning device (18) is in the second configuration, in which the movable plate (20) is substantially opposite to the side plate (19) so as to laterally define at least a portion of the gap (17), and in which the movable plate (20) is rotated relative to the main frame (3) (in particular, relative to the first support portion (22)) (in particular, rotated by an angle ranging from about 70° to about 120°; more particularly, rotated by an angle of about 90°) so as to make the at least a portion of the gap (17) accessible.

4. The compaction system (1) according to claim 2, wherein: The locking system (21) includes: a first coupling element (24), which is integral with one of the movable plate (20) and the second support part (23) and is capable of moving between a retracted position and a removal position; a second coupling element, which is integral with the other of the movable plate (20) and the second support part (23) and is configured to receive the first coupling element (24); and an actuator (25), which is used to operate the first coupling element (24) between the retracted position and the removal position so that the positioning device (18) is transformed from the first structure to the second structure.

5. The compaction system (1) according to claim 2, wherein: The main frame (3) comprises: a vertical first support (33), which is arranged on the first side (L1) of the compacting device (2) and carries the side plate (19); and at least one cross member (34), which connects the first support (33) to the second support part (23).

6. The compaction system (1) according to claim 1, wherein: The compacting device (2) comprises a further belt compacting device (12), the further belt compacting device (12) in turn comprising a further plurality of rollers (13) having horizontal axes and a further belt (14), at least one of the further plurality of rollers (13) being a motor driven roller (13), the further belt (14) being wound around the further plurality of rollers (13) to define a further compacting surface (15) with its upper branches; The conveying surface (5) is in contact with (in particular coincides with) the further compacting surface (15).

7. The compaction system (1) according to claim 1, wherein: The pressing assembly (10) is arranged at a compacting station (11) along the conveying path (P) and comprises a pair of pressing rollers (16a, 16b) having a horizontal rotation axis orthogonal to the conveying direction (A); A first pressing roller (16a) of the pair of rollers (16a, 16b) is arranged below the conveying surface (5); The second pressing roller (16b) of the pair of pressing rollers (16a, 16b) is in contact with the inner surface of the belt (8) of the belt compacting element (6); The pressing rollers (16a, 16b) are movable relative to each other to vary the extension (particularly the thickness) of the gap (17) at the compacting station (11) so as to compact the layer of powder material.

8. The compaction system (1) according to claim 1 comprises a lifting assembly (32), which is operably connected to the belt compacting element (6) and can be operated to act on the inner surface of the pressing belt (8) to lift the pressing belt (8) relative to the multiple rollers (7a, 7b) to facilitate the removal (in particular, slipping) of the pressing belt (8).

9. A method for replacing a pressing belt (8) of a compacting system (1) according to any one of the preceding claims, the replacement method comprising the following steps: an opening step during which the positioning device (18) is actuated to change from the first configuration to the second configuration; a preparation step, during which the pressing belt (8) is released; a removal step, during which the pressing belt (8) is removed from the compacting device (2); an inserting step during which a new pressing belt (8) is fitted on (around) the plurality of rollers (7a, 7b); and A closing step during which the positioning device (18) is operated to transition from the second configuration to the first configuration.

10. The replacement method according to claim 9, wherein: The preparation step comprises a first movement sub-step, during which one roller (7a, 7b) of the plurality of rollers (7a, 7b) is translated parallel to the conveying direction (A) to loosen the pressing belt (8).

11. The replacement method according to claim 9, for replacing the pressing belt (8) of the compacting system (1) according to claim 7, wherein: The preparation step includes a second moving sub-step, during which the second pressing roller (16b) is translated in a direction (B) perpendicular to the conveying surface (5) to increase the above-mentioned gap (17) and facilitate the removal of the pressing belt (8).

12. The replacement method according to claim 10, which is used to replace the pressing belt of the compaction system according to claim 8, comprises a lifting step, which is at least partially before the removing step, and during the lifting step, the lifting assembly (32) lifts the pressing belt (8) to the height of the upper end of the main frame (3) on the second side (L2) relative to the multiple rollers (7a, 7b).

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