Aligner device for ceramic slabs

Abstract

Aligner device for aligning ceramic slabs, comprising: a transport plane (2), movable along a transport direction (X); a manipulator (3), provided with gripping means (31,32) for one or more slabs aligned in a row along a first direction (Y) and configured to translate the gripping means (31,32) between said transport plane (2) and at least one entry or exit station of the ceramic slabs; a movable support (4), which defines a support plane for one or more slabs aligned in a row along the transport direction (X) and is configured to pick up or deposit the ceramic slabs on the transport plane (2); said movable support (4) is movable with respect to the transport plane (2) along at least one vertical direction between a lower position, in which it defines a support plane placed below the transport plane (2), and an upper position, in which it defines a support plane arranged above the transport plane (2); said movable support (4) is arranged so that, in the upper position, it is capable of interacting with the manipulator (3).

Description

[0001] ALIGNER DEVICE FOR CERAMIC SLABS

[0002] The present invention relates to an aligner device, particularly, but not exclusively, for slab-like products, such as ceramic slabs or tiles or panels or slabs in general such as glass slabs, wood panels or slabs in general of different types of material.

[0003] In a production line for ceramic slabs or tiles, a transfer step is included in which the products, exiting the kiln, are fed to a subsequent transport line.

[0004] For process economy, the products exiting the kiln are deposited, by means of known devices, on transportable support surfaces, also called "platforms". The products are arranged on the platforms with a matrix distribution, i.e., they are arranged according to a rectangular or square grid in relation to the shape and dimensions of the products and the platforms. The product matrix is commonly referred to as "quadrotta", or square set of products.

[0005] Once loaded with products, the platforms are transported to an aligner device, which typically comprises a gripping means, for the slabs or tiles supported on the platform, and a sorting system, which takes successive rows of products from the square set of products and feeds such rows to a conveyor, aligned with a predetermined transport direction.

[0006] The aligner devices currently available are quite complex. In fact, the gripping means is in the form of a rather bulky and heavy plate, associated with an anthropomorphic robotic arm or a portal structure. The plate is provided with suction cups or the like, configured to adhere to the products arranged on the platform so as to pick up the entire square set of products. The plate transfers the square set of products to the sorting system, which, in turn, comprises other handling systems, such as roller conveyors and belt conveyors, to separate the rows of products from the square set of products.

[0007] In addition to being rather bulky and complex, the current aligner devices are not very flexible with respect to a change in the size of the products, slabs or tiles. The object of the present invention is to provide an aligner device which enables the features of the current sorting devices to be improved.

[0008] An advantage of the present invention is that it makes it possible to considerably simplify the structure and footprint of the current sorting devices.

[0009] Another advantage of the present invention is to allow greater operating flexibility, quickly adapting to the changes in the size of the products.

[0010] Another advantage of the present invention is to allow the orderly transfer of the products with considerably reduced times with respect to the current sorting devices.

[0011] Additional features and advantages of the present invention will become more apparent from the detailed description that follows of one embodiment of the invention in question, illustrated by way of non-limiting example in the appended figures, in which:

[0012] Figure 1 shows an isometric view of the aligner device according to the present invention;

[0013] Figures 2 to 9 show views on an enlarged scale of some operating steps in sequence of the aligner device according to the present invention. The aligner device according to the present invention is particularly effective for arranging slab-like products in a row in an orderly manner, such as products in the form of ceramic slabs or tiles. The term "slabs" will be used below to indicate such products.

[0014] In the case of products in the form of ceramic slabs or tiles, the latter can be placed in an end station (E) of the aligner device. The end station (E) can be an entry station or an exit station, depending on the function assumed by the aligner device.

[0015] In a first function, the aligner device according to the present invention is suitable both for picking up the slabs from the end station (E), and for arranging them aligned in an ordered row. In a second function, the aligner device according to the present invention is suitable for picking up the tiles from an ordered row, so as to arrange them in the end station (E) according to a desired arrangement.

[0016] The first function refers particularly to the case mentioned in the introductory part of the description, i.e., to the typical case in which the ceramic slabs, exiting the kiln, are deposited on conveyable support planes (P), also called platforms. In this case, the end station (E) is an entry station, in which the platforms (P) are placed gradually. The slabs are arranged on the platforms (P) in groups configured as a matrix, i.e., they are arranged according to a rectangular or square grid in relation to the shape and dimensions of the products and the platforms (P). The product matrix is commonly referred to as "quadrotta", or square set of products. In the case of slabs in the form of slats, or large slabs, the product matrix could comprise two or more slabs side by side with each other, or a single slab.

[0017] The second function instead refers to a plant request which is substantially opposite to the previous one, i.e., to a case in which it is requested to pick up the slabs ordered in a row, coming from a transport line, to arrange them in the end station (E) according to a desired arrangement, for example to form a square set of products of the type described above. In this case, the end station (E) is an exit station.

[0018] The aligner device according to the present invention comprises a transport plane (2), movable along a transport direction (X). In the depicted, preferred but not exclusive embodiment, the transport plane (2) comprises a pair of motorized belts, arranged parallel to the transport direction (X) and separated by a distance suitable to ensure the support of the slabs (L). Two upper sections of the belts, movable along the transport direction (X) in an advancement direction, are tangent to a substantially horizontal plane, on which the slabs (L) move thanks to the sliding of the belts themselves.

[0019] Preferably, but not necessarily, the distance between the motorized belts is adjustable by means known in the art.

[0020] The aligner device according to the present invention further comprises a manipulator (3), provided with a gripping means (31 ,32) for one or more slabs aligned in a row along a first direction (Y). The manipulator is configured to translate the gripping means (31 ,32) between said transport plane (2) and said end station (E).

[0021] The manipulator (3), for example, is in the form of a robotic arm provided with a plurality of rotation axes, to allow a movement of the gripping means (31 ,32) in space. In a particularly advantageous embodiment, which will be better described below, the manipulator (3) comprises a considerably lighter and more rigid structure than a robotic arm.

[0022] The gripping means (31 ,32) is configured to be able to grip and release, on command, one or more slabs aligned in a row along a first direction (Y). In particular, the gripping means (31 ,32) is configured to be able to grip and retain a row of slabs (L) aligned along the first direction (Y), and to release them in a subsequent step.

[0023] In a first case, corresponding to the first function described above, the row of slabs (L) is positioned on a platform (P). The first direction (Y) could be parallel or non-parallel with respect to the transport direction (X). In this case, the gripping means (31 ,32) is arranged to grip at least one row of slabs (L), and to release them on the transport plane (2), bringing the first direction (Y) to be parallel to the transport direction (X), by means of the translation operated by the manipulator (3).

[0024] In a second case, corresponding to the second function described above, the row of slabs (L) is positioned on the transport plane (2), aligned along the transport direction (X). In this case, the gripping means (31 ,32) is arranged to grip at least one row of slabs (L) from the transport plane (2), and to release them in the end station (E), for example on a platform (P), due to the translation operated by the manipulator (3). The slabs (L) are released in the end station (E) aligned along the first direction (Y), which could be parallel or non-parallel with respect to the transport direction (X).

[0025] In the depicted, preferred but not exclusive embodiment, the gripping means (31 ,32) comprises a plurality of suction cups (310,320), aligned along said first direction (Y). Preferably, the gripping means (31 ,32) comprises a first bar (31 ), provided with a plurality of suction cups (310) aligned along said first direction (Y), and a second bar (32), provided with a plurality of suction cups (320) aligned along said first direction (Y). Each bar (31 ,32) is therefore configured to grip and retain a row of slabs (L), or an elongated slab (L), aligned parallel to the first direction (Y). The two bars (31 ,32) are substantially side by side with each other, separated by an adjustable distance, so as to retain the rows of slabs (L) parallel and side by side with each other.

[0026] The suction cups (310,320) can be activated and deactivated independently of one another, as a function of the shape and size of the slabs (L) to be picked up. In other words, each suction cup (310,320) can be individually activated and deactivated. This allows to activate or deactivate the suction cups that are actually necessary, at a given time, for picking up the slabs (L). Each slab (L) can be picked up and retained by one or more suction cups simultaneously, as a function for example of the number, shape and size of the slabs themselves. Suction cups suitable for the purpose summarized above are known in the art, and will not be further described.

[0027] Preferably, but not necessarily, the first and the second bar (31 ,32) are movable on a horizontal plane independently of each other. The possibility of moving on a horizontal plane allows to adjust the vertical alignment, with respect to a desired position, of each bar. For example, it is possible to adjust the vertical alignment on an underlying row of slabs (L). Furthermore, the possibility of moving on a horizontal plane allows to adjust the distance between the bars (31 ,32) themselves.

[0028] Preferably, but not necessarily, the gripping means (31 ,32) is rotatable about a vertical axis (Z), to allow to rotate the first direction (Y) on a horizontal plane. The possibility of rotation about a vertical axis (Z) substantially allows to rotate the first direction (Y) in a desired position, so as to be able to arrange a row of slabs (L) parallel to the transport direction (X). In such a case, the first direction (Y), along which the rows of slabs (L) are aligned, can be oriented in any manner with respect to the transport direction (X).

[0029] In the depicted, preferred but not exclusive embodiment, the gripping means (31 ,32) comprises a support plate (33), associated with the manipulator (3) by means of a joint (34), rotating about the vertical axis (Z). Motor means not shown is arranged to actuate the rotation of the support plate (33).

[0030] In the embodiment depicted, the bars (31 ,32) are associated with the support plate (33), with the possibility of sliding on a horizontal plane. To this end, the bars (31 ,32) are associated with sliding guides (35), in turn connected to the support plate (33). Motor means of known type is arranged to actuate the sliding of each bar (31 ,32) along the sliding guides (35).

[0031] Advantageously, the aligner device according to the present invention comprises a movable support (4), which defines a support plane for one or more slabs aligned in a row along the transport direction (X). Such a movable support (4) is configured to pick up or deposit the ceramic slabs on the transport plane (2). In particular, the movable support (4) is positioned at an exchange section (21 ) of the transport plane (2). Such an exchange section (21 ) is substantially a portion of the transport plane (2) at which a row of slabs is deposited or picked up by the mobile support (4). In the depicted embodiment, the exchange section (21 ) is placed at one end of the transport plane (2).

[0032] The movable support (4) is movable with respect to the transport plane (2) along at least one vertical direction between a lower position, in which it defines a support plane placed below the transport plane (2), and an upper position, in which it defines a support plane placed above the transport plane (2). Furthermore, the movable support (4) is arranged so that, in the upper position, it is capable of interacting with the manipulator (3). The movement of the movable support (4) is actuated by means of a motor device, comprising for example one or more actuators, electrical or hydraulic, with control systems configured to control the actuators themselves. Various examples of motor devices suitable for carrying out the described function are known to the person skilled in the art, and will thus not be described in further detail.

[0033] The movable support (4) allows to greatly speed up the deposition or picking up of the rows of slabs (L) on the transport plane (2).

[0034] For example, in the case of deposition, two rows of slabs (L) can be deposited in rapid succession on the transport plane (2) in the following manners. A first row can be deposited on the movable support (4), previously placed in the upper position. After receiving the first row, the movable support (4) is arranged in the lower position, depositing the first row on the transport plane (2), in particular on the exchange section (21 ). The transport plane (2) can be activated to transport the first row in advancement along the transport direction (X) and, simultaneously, the movable support (4) returns to the upper position in which it can receive a second row, while the first row continues to advance along the transport direction (X), freeing the exchange section (21 ) for the second row. When the exchange section (21 ) is free, the movable support (4) lowers into the lower position, depositing the second row of slabs (L). The cycle can be repeated for a desired number of times, as a function of the number of rows to be loaded on the transport plane (2). In the embodiment depicted, the rows of slabs are led to the movable support (4) by means of the manipulator (3). In particular, the gripping means (31 ,32) can lead two rows of slabs, each of which is retained by a bar (31 ,32) of suction cups (310,320), and can be deposited in rapid succession on the movable support (4), to be transported to a next destination by means of the transport plane (2), in the manner described above. As already mentioned, the gripping means (31 ,32), provided with two bars (31 ,32) of suction cups, picks up two rows of slabs (L) from the end station (E). The two rows of slabs (L) are retained by the suction cups (310,320) parallel to each other. Having reached the area of the exchange section (21 ), each row is vertically aligned to the movable support (4) by means of a horizontal translation of the relative bar (31 ,32), or by means of a movement imposed by the manipulator (3), if the bars (31 ,32) are not movable horizontally.

[0035] In the case of picking up the rows from the transport plane (2), the sequence of operations described above for the deposit is reversed. In particular, the movable support (4) is initially in the lower position. A first row of slabs is led from the transport plane (2) to the exchange section (21 ). Once the first row of slabs has arrived, the movable support (4) rises into the upper position, placing the first row on the gripping means (31 ,32) of the manipulator (3). The first row of slabs can then be picked up by the gripping means. Subsequently, the movable support (4) returns to the lower position, while a second row of slabs is led to the exchange section (21 ). When the second row of slabs is in the exchange section (21 ), the movable support (4) rises into the upper position, in which the second row can be picked up by the gripping means (31 ,32). The cycle can be repeated for the desired number of rows of slabs. In the embodiment depicted, in which the gripping means (31 ,32) is configured to operate on two rows of slabs, the movable support (4) allows picking up two rows of slabs in rapid succession. Also in this case, in the embodiment in which the gripping means (31 ,32) is provided with two bars (31 ,32) of suction cups, the gripping means (31 ,32) picks up two rows of slabs (L) in succession from the movable support (4). Having reached the area of the exchange section (21 ), each bar (31 ,32) is vertically aligned to the movable support (4) by means of a horizontal translation, or by means of a movement imposed by the manipulator (3), if the bars (31 ,32) are not movable horizontally.

[0036] The movable support (4) is shaped so as not to interfere with the transport plane (2) during the vertical translation between the lower position and the upper position. In the depicted, preferred but not exclusive embodiment, the movable support (4) comprises at least a first support (41 ), movable along a vertical direction between the lower position and the upper position. In the upper position, the first support (41 ) protrudes at least partially above the transport plane (2). In the lower position, the first support (41 ) is arranged below the transport plane (2). To this end, the first support (41 ) is placed next to the transport plane (2), and in particular next to the exchange section (21 ), so as to be able to move vertically without interfering with the transport plane (2).

[0037] Preferably, the movable support (4) comprises a second support (42), alongside the first support (41 ) on the opposite side of the transport plane (2). In other words, the first and the second support (41 ,42) are located on opposite sides of the transport plane (2). The transport plane (2) is interposed between the two supports (41 ,42). The width of the transport plane (2), measured perpendicular to the transport direction (X) on a horizontal plane, allows the slabs (L) to protrude laterally from the transport plane (2) for a sufficient portion to allow contact with the supports (41 ,42), which are placed next to the transport plane (2). That is, the width of the transport plane (2), measured perpendicularly to the transport direction (X) on a horizontal plane, is adjusted so as to be smaller with respect to the width of the slabs (L). The distance between the supports (41 ,42), measured perpendicularly to the transport direction (X) on a horizontal plane, is less than the width of the slabs (L) and greater than the width of the transport plane (2).

[0038] Preferably, but not necessarily, the distance between the supports (41 ,42) is adjustable perpendicularly to the transport direction (X) on a horizontal plane. To this end, adjustment means, known in the art and not described in detail, is provided.

[0039] The first and the second support (41 ,42) have a conformation suitable for supporting one or more slabs aligned in a row along the transport direction (X). In the depicted, preferred but not exclusive embodiment, the first and the second support (41 ,42) comprise a respective bar, arranged parallel to the transport direction (X).

[0040] In a particularly advantageous but not exclusive embodiment, the manipulator (3) comprises a column (3a), rotatable about a vertical axis. An arm (3b) is associated with the column (3a), with the possibility of sliding vertically along the column (3a) itself. The arm (3b) protrudes radially from the column (3a), i.e., extends along a radial direction with respect to the vertical axis of rotation of the column (3a).

[0041] The gripping means (31 ,32) is connected to the arm (3b). Furthermore, the gripping means (31 ,32) is slidable along the arm (3b), moving towards and away from the column (3a).

[0042] The combination of the rotation movements of the column (3a), vertical translation of the arm (3b) and sliding of the gripping means (31 ,32) along the arm (3b), allows to freely move the gripping means (31 ,32) within a predefined working space. In other words, thanks to the configuration of the manipulator (3), the gripping means (31 ,32) can reach substantially any position within a predefined workspace.

[0043] As already mentioned, preferably the gripping means (31 ,32) is rotatable about a vertical axis (Z), to allow to rotate the first direction (Y) on a horizontal plane. The possibility of rotation about a vertical axis (Z) substantially allows to rotate the first direction (Y) in a desired position, so as to be able to arrange a row of slabs (L) parallel to the transport direction (X), starting from any alignment direction of the row of slabs (L). That is, the first direction (Y), along which the rows of slabs (L) are aligned, can be oriented in any manner with respect to the transport direction (X). Thanks to the possibility of rotating the gripping means (31 ,32) about a vertical axis (Z), it is possible to coordinate the rotation of the column (3a) and the gripping means (31 ,32) about the respective vertical axis so as to pick up a row of slabs (L) aligned along any direction and orient the row of slabs (L) parallel to the transport direction (X), or vice versa.

[0044] The structure of the manipulator (3), in the form described above which substantially comprises the column (3a) and the arm (3b), is considerably simpler and lighter with respect to that of an articulated arm, as well as being more rigid and allowing greater precision of the movements of the gripping means (31 ,32). The transport plane (2), the manipulator (3), the gripping means (31 ,32) and the movable support (4) are controlled by a control computer, not depicted. Such a control computer is provided with a control algorithm which is configured to coordinate the movements of the transport plane (2), the manipulator (3), the gripping means (31 ,32) and the movable support (4) so as to follow the cycles of operations described above.

Claims

CLAIMS1 . An aligner device for aligning ceramic slabs, comprising: a transport plane (2), movable along a transport direction (X); a manipulator (3), provided with gripping means (31 ,32) for one or more slabs aligned in a row along a first direction (Y) and configured to translate the gripping means (31 ,32) between said transport plane (2) and at least one end station (E) of the ceramic slabs; characterised in that: it comprises a movable support (4), which defines a support plane for one or more slabs aligned in a row along the transport direction (X) and is configured to pick up or deposit the ceramic slabs on the transport plane (2); said movable support (4) is movable with respect to the transport plane (2) along at least one vertical direction between a lower position, in which it defines a support plane placed below the transport plane (2), and an upper position, in which it defines a support plane arranged above the transport plane (2); in the upper position, said movable support (4) is capable of interacting with the manipulator (3).

2. The aligner device according to claim 1 , wherein: the movable support (4) comprises at least a first support (41 ), movable along said at least one vertical direction between the lower position and the upper position; in the upper position, the first support (41) protrudes at least partially above the transport plane (2); in the lower position, the first support (41 ) is arranged below the transport plane (2).

3. The aligner device according to claim 2, wherein: the movable support (4) comprises a second support (42), alongside the first support (41 ); the first and the second support (41 ,42) have a conformation suitable forsupporting one or more slabs aligned in a row along the transport direction (X).

4. The aligner device according to claim 3, wherein the first and the second support (41 ,42) are arranged at the sides of the transport plane (2).

5. The aligner device according to claim 4, wherein the first and the second support (41 ,42) comprise a respective bar, arranged parallel to the transport direction (X).

6. The aligner device according to any one of the preceding claims, wherein said gripping means (31 ,32) comprises a plurality of suction cups (310,320) aligned along said first direction (Y).

7. The aligner device according to claim 6, wherein said gripping means (31 ,32) comprises a first bar (31 ), provided with a plurality of suction cups (310) aligned along said first direction (Y), and a second bar (32), provided with a plurality of suction cups (320) aligned along said first direction (Y).

8. The aligner device according to claim 7, wherein the first and the second bar (31 ,32) are arranged on a horizontal plane and are movable independently of one another on said horizontal plane, towards or away from one another.

9. The aligner device according to any one of the preceding claims, wherein the gripping means (31 ,32) is rotatable about a vertical axis (Z), to allow to rotate said first direction (Y) on a horizontal plane.

10. The aligner device according to claim 9, wherein in the end station (E), said first direction (Y) has a different inclination with respect to the transport direction (X).11 . The aligner device according to any one of the preceding claims, wherein said manipulator (3) comprises: a column (3a), rotatable about a vertical axis; an arm (3b), associated with the column (3a) and sliding vertically along the column (3a), to which said gripping means is connected (31 ,32); the gripping means (31 ,32) is sliding along the arm (3b).

Images