Portable machine for cutting composite parts

Abstract

The present invention relates to a portable machine (1) for cutting composite material parts. The portable machine (1) includes a compression module (2) including one or more upper rollers (4) and two or more lower rollers (6). The upper rollers (4) are coupled to a mechanism configured to compress the part to be cut by longitudinally moving the upper rollers (4). At least one upper roller (4) is longitudinally offset relative to the adjacent lower roller (6) by an offset angle (α) between 45° and 15°, such that the composite material part is compressed by the rollers (4, 6) in a direction substantially perpendicular to the fiber direction, thereby fracturing, delaminating, and breaking the fibers prior to cutting in a diamond wire cutting module (7).

Description

Detailed Description of the Invention

[0001] [Subject of the present invention] The present invention can be found in the technical field of portable devices and machines for cutting composite materials, in particular machines of the type that include a compression module for compressing and breaking the fibers of the material, followed by a cutting module. More specifically, the subject of the present invention relates to a portable machine for recycling composite materials (e.g., composite materials for wind turbine blades). This portable machine has a configuration of multiple rollers that break and crush the fibers and compress them substantially in that direction, allowing for delamination of the part. This is particularly advantageous for its subsequent cutting and subsequent recycling in the same machine, especially when the cutting is performed with a diamond wire. This combination allows for cutting very thick parts of any type of composite material.

[0002] Background of the Invention Considering the increasing use of composite materials for the production of large structures, one of the advantages is their use in the production of monolithic components, so that maximum benefits can be achieved. At the end of their useful life, these components need to be transferred to recycling plants. This needs to be done with as little impact as possible on the environment.

[0003] Disassembling large composite parts and transporting them to recycling plants requires cutting them into dimensions that can be easily transported by conventional means, allowing for the optimization of transportation resources and therefore reducing CO2 emissions during transportation.

[0004] Several portable machines for cutting composite parts are known in the prior art.

[0005] For example, document ES2394704A1 describes a portable guillotine-type cutting machine. Guillotine cutting does not allow cutting all types of composite materials or all thicknesses. In addition, the same document describes a compression process using symmetrically arranged rollers in a row, but the results are not satisfactory in terms of delamination, since the described roller configuration does not allow crushing and breaking of the fibers. All of this affects the final cutting result, which is accompanied by significant limitations. It has been found that this compression process using symmetrically arranged rollers does not allow delamination of the material, i.e., it does not allow breaking of the various fiber layers that make up the composite material.

[0006] Furthermore, known machines for cutting composite materials generate large amounts of dust and solid particles that are harmful to the operator and pollute the surrounding area (e.g., wind farms). No known solution allows decanting and reducing the amount of emitted dust particles that not only pollute but can also affect the health of the cutting machine operator.

[0007] Description of the Invention The present invention aims to solve some of the problems mentioned in the prior art, and more particularly, the present invention relates to a portable machine for cutting parts of composite material, comprising at least one compression module and one cutting module.

[0008] The compression module includes a row of one or more upper rollers and a lower row of two or more lower rollers coupled to an actuator operatively coupled to a mechanism configured to longitudinally move the rollers to compress the part intended to be cut in operation, the mechanism further configured to rotate the rollers in operation such that the part of composite material is moved tangentially relative to the rollers until it reaches the cutting module.

[0009] Preferably, at least one upper roller is longitudinally offset with respect to the adjacent lower roller, the offset angle being comprised between 45°±15°, so that the composite material part is compressed by the rollers in a direction substantially perpendicular to the fiber direction, thereby crushing and breaking the fibers before cutting in the cutting module. In this way, the rollers exert pressure on the interlayer region of the part.

[0010] The compression module may, for example, include two upper rollers in an upper row and three lower rollers in a lower row, each of the rollers being longitudinally offset at an angle of 45±10° relative to the lower rollers immediately adjacent to it.

[0011] Furthermore, the compression module may include rollers forming various compression stations (various openings) arranged in a triangle with rollers positioned at different distances from each other in a cascade configuration progressing from larger openings to smaller openings. In this case, large parts are subsequently crushed and broken so that they can be moved to roller stations with smaller openings. In this embodiment, the stations with the largest openings at the machine entrance can have rollers positioned symmetrically above and below each other, since these stations are solely intended to compress large parts to a size acceptable to the main offset rollers. Subsequent removal is achieved in subsequent stations with rollers offset by 45±10° from each other.

[0012] According to the invention, the at least one upper roller or each upper roller of said plurality of upper rollers is arranged at 45±10° to the roller immediately below it, so as to provide compression in the direction of the fibers. However, the number of rollers and / or the number of stations defined by the triangle of rollers is dictated by the design of the machine based on the type, size and thickness of the parts to be cut.

[0013] In one advantageous embodiment, each upper roller is offset at an angle of 60° from the two lower rollers adjacent to it, and the compression module therefore has a staggered arrangement of rollers forming equilateral triangular groups.

[0014] Additionally, in one preferred embodiment, the surface of the upper roller is smooth, while the surface of the lower roller has angled or spiral projections to aid in gripping the part to be cut.

[0015] Preferably, the projections have a frustopyramidal cross section and are offset from the longitudinal axis by approximately 30°.

[0016] The above solutions promote delamination of the material (breaking (splitting) the different fiber layers that make up the composite material) because they exert a force on the interlayer area. On the other hand, some composite materials have a core of other types of material, such as wood or foam, which is separated from the composite material when it passes through the above roller configuration. These two functions, separation and delamination, are as important as the cutting itself, because they allow for better compaction of the material (which increases the amount of material that can be transported by truck), thereby promoting improved recycling of composite materials.

[0017] After the compression module, once the composite part has been delaminated in the compression module by breaking and crushing the fibers, the part is moved by the rotation of the pulling rolls to a cutting module located after the compression module.

[0018] The cutting module, according to one preferred embodiment of the present invention, comprises a cutting element made of a diamond wire, preferably coupled to two pulleys, one of which is a towing pulley, such that the diamond wire is configured to descend longitudinally to cut the composite piece.

[0019] This diamond wire cutting solution, together with the roller configuration described above, makes it possible to cut any composite material (fiberglass, carbon, or aramid) and any thickness, unlike other known systems.

[0020] Additionally, the cutting module may include a cooling and purified water dispenser configured to cool and purify the diamond wire as it cuts the composite piece.

[0021] To reduce the contamination of dust particles and reuse the cooled purified water in a closed circuit, the machine may further comprise a module for purification, water recirculation and decantation of solid particles. a tank located in the lower part, configured to store the cooled purified water and to decant solid particles contained in the water stored in the tank resulting from the cutting; a filter for filtering out particles carried by the water stored in the tank; a pumping element configured to pump the filtered water to the water dispenser for reuse.

[0022] In a preferred embodiment, the water diffuser is configured to create an atmosphere of water particles along the entire length of the cut, which allows dust particles to settle with the water.

[0023] Preferably, the machine comprises, on the one hand, a first group of diffusers or nebulizers that neutralize (neutralize) the emission of dust emitted by cutting, and, on the other hand, another group of diffusers is contained in the module, which acts directly on the cutting zone and prevents the emission of a significant part of the dust from the cutting zone. It should be noted that this water is not lost, since it enters a closed circuit for recycling and purifying the water.

[0024] Finally, in a preferred embodiment, the cutting machine includes two beds, a front bed and a rear bed, both of which are retractable and foldable and support the parts to be cut at an entrance portion forward of and adjacent to the compression module, and at an exit portion rearward of and adjacent to the cutting module.

[0025] A second aspect of the invention relates to a vehicle including a cutting machine according to any of the variants or embodiments described above. This vehicle is driven to the location closest to where the cutting is to be performed, for example at a wind farm, and the material is then transported to a recycling plant. This allows for the optimization of transport resources to move the parts, thereby reducing CO2 emissions during transport.

[0026] Another environmental objective is to cut without emitting particles into the atmosphere so that it can be used in any environment. Considering the variety of possible locations of the parts to be cut and the characteristics of the dust that can be emitted, the above-mentioned purification, water recirculation and solid particle decanting modules are very important for achieving the aforementioned objective.

[0027] DESCRIPTION OF THE DRAWINGS In order to supplement the description provided herein and to help make the features of the invention more readily comprehensible, said description is accompanied by a set of drawings which, in accordance with one practical, exemplary and preferred embodiment thereof, constitute a very important part thereof, the following of which are expressed by way of example and not by way of limitation: FIG. 1 is a perspective view of a preferred embodiment of a cutting machine showing the front retractable bed, the compression module, the diamond wire cutting module, the tank for recirculating cooling water, and the rear retractable bed.

[0028] FIG. 2 is a schematic front view of the preferred embodiment of FIG.

[0029] FIG. 3 is a schematic front view of a preferred embodiment of a compression module according to the present invention, illustrating the staggered configuration of the rollers and the optimum offset angle range for delamination.

[0030] Preferred Embodiments of the Present Invention A detailed description of one preferred exemplary embodiment of the subject matter of the present invention is provided below with the aid of the accompanying drawings mentioned above.

[0031] As shown in Figure 1, the subject of the present invention relates to a portable machine (1) for cutting composite material parts, comprising a compression module (2) and a cutting module (7). It comprises an upper row (3) provided with one or more upper rollers (4) and a lower row (5) provided with two or more lower rollers (6). The rollers (4) are coupled to an actuator operatively coupled to a mechanism configured to compress the part intended to be cut by longitudinally moving the rollers (4), the mechanism further configured to rotate the rollers (4, 6) in such a way that, in operation, the part of composite material is moved tangentially relative to the rollers (4, 6). At least one upper roller (4) is longitudinally offset with respect to the lower roller (6) adjacent to it, the offset angle (α) being comprised between 45°±15°, so that the composite material part is compressed by the rollers (4, 6) in a direction substantially perpendicular to the fiber direction, thereby crushing and breaking the fibers before cutting in the cutting module (7).

[0032] More specifically, in the preferred embodiment shown in FIG. 1, each upper roller (4) is offset at an angle (α) of 60° from the two lower rollers (6) adjacent to it, and the compression module (2) therefore has a staggered arrangement of rollers (4, 6) forming equilateral triangular groups.

[0033] Furthermore, FIG. 1 shows that in a preferred embodiment, the lower roller (6) includes a protrusion offset from the longitudinal axis to favor gripping of the part intended to be cut and to prevent slippage of the part.

[0034] Furthermore, as a cutting element (7), the cutting module (7) comprises a diamond wire coupled to two pulleys (9, 10), one of which is a traction pulley such that the diamond wire is configured to descend longitudinally to cut the composite material part.

[0035] Figure 2 is a schematic front view of the preferred embodiment of Figure 1, illustrating the aforementioned cutting machine. As can be seen in Figure 2, the cutting machine (1) further includes two beds (14, 15), a front bed and a rear bed, which are both retractable and support the parts at an entrance portion in front of and adjacent to the compression module (2) and an exit portion in rear of and adjacent to the cutting module (7).

[0036] Additionally, to control dust emissions, the machine includes a water diffuser (not shown) along the length of the diamond wire and a tank (13) that acts as a decanter for solid particles. This water passes through a fine filtration system, is collected, and pumped back to the water dispersion system that projects water onto the parts and diamond wire.

[0037] Preferably, the cutting machine (1) comprises, on the one hand, a first group of diffusers or nebulizers (not shown) that neutralize (neutralize) the emissions of dust emitted by cutting, and, on the other hand, another group of diffusers is contained in the module, which acts directly on the cutting zone and prevents the emission of a significant part of the dust from the cutting zone. It should be noted that this water is not lost, since it enters a closed circuit for recirculating and purifying the water.

[0038] In a preferred embodiment, the cutting machine (1) includes partitions between different sections to prevent both water and dust from passing to other parts of the cutting machine (1).

[0039] The assembly is designed to be autonomous and therefore may have a generator that provides the energy necessary to power all the elements described in its operation.

[0040] Figure 3 is a schematic front view of a preferred embodiment of the compression module (2). It shows a staggered arrangement of rollers (4, 6) offset at 60° from each other. Each group of three rollers (4, 6) forms an equilateral triangle.

[0041] Additionally, FIG. 3 illustrates the offset angle between rollers, showing a multiple roller configuration and the optimal offset range (specifically, 45±10°) for optimal delamination and fracture of the internal fibers according to the present invention. [Brief explanation of the drawings]

[0042] [Figure 1] FIG. 1 is a perspective view of a preferred embodiment of a cutting machine showing the front retractable bed, the compression module, the diamond wire cutting module, the tank for recirculating cooling water, and the rear retractable bed. [Figure 2] FIG. 2 is a schematic front view of the preferred embodiment of FIG. 1. [Figure 3] FIG. 1 is a schematic front view of a preferred embodiment of a compression module according to the present invention, illustrating the staggered configuration of the rollers and the optimal offset angle range for delamination.

Claims

1. A portable machine (1) for cutting parts of composite material, comprising: an upper row (3) provided with one or more upper rollers (4); a lower row (5) provided with two or more lower rollers (6); a compression module (2) comprising: a mechanism configured to compress the part intended to be cut by longitudinally moving the upper roller (4), the upper roller (4) being coupled to an actuator operatively coupled to a mechanism further configured to rotate the rollers (4, 6) in operation such that the part of composite material is moved tangentially relative to the rollers (4, 6); a cutting module (7) arranged after the compression module (2), the cutting module (7) including at least one cutting element (8) configured to cut the piece of composite material compressed in the compression module (2); A portable machine (1) comprising: At least one upper roller (4) is longitudinally offset with respect to a lower roller (6) adjacent to said upper roller (4); the offset angle (α) is comprised between 45°±15°, so that the part of composite material is compressed by the rollers (4, 6) in a direction substantially perpendicular to the direction of the fibers, thereby crushing and breaking the fibers before cutting in the cutting module (7).

2. 2. Cutting machine according to claim 1, wherein the at least one upper roller (4) is offset at an angle (α) of 60° relative to the two lower rollers (6).

3. Each upper roller (4) is offset at an angle (α) of 60° with respect to the two lower rollers (6) adjacent to it; 2. Cutting machine according to claim 1, wherein the compression module (2) has a staggered arrangement of rollers (4, 6) forming equilateral triangular groups.

4. 4. The cutting machine according to claim 1, wherein one or more of the lower rollers (6) have protrusions inclined relative to their longitudinal axis to favour gripping of the piece of composite material.

5. The compression module (2) two upper rollers (4) in the upper row (3); three lower rollers (6) in the lower row (4); Including, 2. Cutting machine according to claim 1, wherein each of said rollers is longitudinally offset with respect to its two immediate neighbouring lower rollers (6) by an angle (α) of 45±10°.

6. The cutting element (7) of the cutting module (8) is a diamond wire coupled to two pulleys (9, 10), 2. A portable machine according to claim 1, wherein one of the pulleys (9, 10) is a traction pulley so that the diamond wire is configured to descend longitudinally to cut the piece of composite material.

7. 5. The portable machine of claim 4, wherein the cutting module (7) further comprises a cooling and purifying water dispenser configured to cool and purify the diamond wire throughout the cut as the diamond wire cuts the piece of composite material.

8. further comprising a purification, water recirculation and solid particle decant module (12); The purification, water recirculation and solid particle decant module (12) comprises: a tank (13) located in the lower part, configured to store the cooled purified water and to decant solid particles from the water stored in the tank (13) resulting from the cutting; a filter for filtering particulates carried by the water stored in the tank; a pumping element configured to pump the filtered water to the water dispenser for reuse; 6. The portable machine of claim 5, comprising:

9. It includes two beds (14, 15), a front bed and a rear bed, 2. The portable machine of claim 1, wherein the front bed and the rear bed are retractable together and support the parts at an entrance portion forward of and adjacent to the compression module (2) and at an exit portion rearward of and adjacent to the cutting module (7).

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