An apparatus for cutting a plurality of grooves in a workpiece

Abstract

There is provided an apparatus for cutting a plurality of grooves in a workpiece. The apparatus is computer numerically controlled and configured to cut the plurality of grooves in accordance with information defining a cutting pattern. The apparatus comprises a controller for receiving information comprising numerical data defining a cutting pattern for a workpiece; at least one table for supporting a first surface of a respective workpiece; and a cutting machine, comprising a plurality of cutters. The cutting machine is configured such that a position in a direction parallel to the x-axis of at least one cutter of the plurality of cutters is controllable by the controller relative to a position in the direction parallel to the x-axis of another cutter of the plurality of cutters to enable a spacing between at least two adjacent grooves of the plurality of grooves to be controlled. The cutting machine is also configured such that a position in a direction parallel to the z-axis of at least one cutter of the plurality of cutters is controllable by the controller to enable a depth of at least one groove to be controlled. At least one of the cutting machine and the at least one table are movable, relative to the other, for cutting the plurality of grooves across the surface of the workpiece.

Description

GROOVE CUTTING

[0001] Technical Field

[0002] The present disclosure relates to an apparatus for cutting a plurality of grooves in a workpiece.

[0003] Background

[0004] It is well known to those skilled in the art of manufacturing to provide a workpiece or structural material having a pattern of cuts or grooves in one or more surfaces of the structural material. The grooves may provide a functionality to the structural material over and above the material’s inherent qualities or characteristic.

[0005] For example, in the art of wind turbine manufacture it is known to provide foam or balsa wood as a core structural material in a core material kit. A pattern of grooves may be cut into one or more surfaces of the material at a selected spacing and to a selected depth, to make the material more conformable or drapable. For example, the grooves may be provided so that the core material can more easily conform to an inner surface of a wind turbine blade mould. Additionally or alternatively, grooves may be provided in a surface of the material so that the grooves promote resin transfer along or through the core material during a resin transfer moulding (RTM) process.

[0006] For example, EP4065841 A1 discloses a core material for a wind turbine blade, the core material having grooves cut therein to enhance drapability of the core material.

[0007] The present disclosure has identified a problem that in known methods there is a lack of flexibility with respect to the pattern of grooves that can be made. For example, it is known for a cutting machine to have a plurality of cutting elements arranged at a fixed spacing from each other. Multiple grooves can be cut in a single pass of a workpiece, but the spacing between adjacent grooves and depth of each groove is fixed or at least cannot be easily adjusted between “runs”. As such, for efficiency of manufacture standard groove depths and groove spacings may be provided, even where those spacings and depths may be sub-optimal for a given purpose.

[0008] Accordingly it is identified in the present disclosure that there is a need for a cutting apparatus that provides enhanced flexibility with respect to enabling an operator to cut a variety of groove patterns in to a workpiece.

[0009] Summary

[0010] In a first aspect there is provided an apparatus for cutting a plurality of grooves in a workpiece, according to claim 1 .

[0011] Further optional features are set forth according to the dependent claims.

[0012] Brief Description of Drawings

[0013] Figure 1 schematically shows an apparatus for cutting a plurality of grooves in a workpiece, according to an example of a first embodiment.

[0014] Figure 2 further shows the apparatus for cutting a plurality of grooves in a workpiece, according to the example of the first embodiment.

[0015] Figure 3 shows in more detail the cutters of the apparatus, according to the first embodiment.

[0016] Figure 4 schematically shows an apparatus for cutting a plurality of grooves in a workpiece, according to an example of a second embodiment.

[0017] Figure 5 is a plan view of the apparatus of Figure 4.

[0018] Figure 6 shows in more detail a component of the apparatus of the second embodiment.

[0019] Figure 7 schematically shows a housing that could be used to house parts of the apparatus of the first and second embodiments.

[0020] Detailed Description

[0021] Figures 1 and 2 schematically show a manufacturing area or system 100.

[0022] The system 100 comprises an apparatus 102. The apparatus 102 is for cutting a plurality of grooves in a workpiece 104 (see Figure 2). The workpiece 104 may also be referred to as a material or section of material, or a section of core material, or the like. The apparatus 102 is computer numerically controlled (CNC) and is configured to cut the plurality of grooves in accordance with information defining a cutting pattern. One or more cutting patterns may be generated by a human operator via an associated computer aided drawing package, and / or one or more cutting patterns may be generated by a computer program based on one or more design parameters, and the one or more cutting patterns may be sent or transmitted to the apparatus 102.

[0023] As shown in Figure 1 , the apparatus comprises a controller which is schematically shown at 106. The controller 106 is configured for receiving numerical data defining a cutting pattern for a workpiece, such as workpiece 104. Other workpieces may be subjected to a same or a different respective groove cutting pattern. The controller 106 may comprise one or more memories and one or more processors. The controller 106 may comprise a microcontroller.

[0024] A power source is schematically shown at 109, for powering one or more components within the system. In some examples, the power source 109 comprises mains electrical power. In some examples an auxiliary power supply may also be provided, in case of failure of the power source 109.

[0025] The apparatus 102 comprises at least one table 112 for supporting a first surface of a respective workpiece, such as workpiece 104. For example, the first surface of the workpiece may comprise a lower surface or bottom surface 103 of workpiece 104. In some examples the at least one table 112 is height adjustable, for example via a scissor lift mechanism, to suit a height of operator 101 .

[0026] The apparatus 102 comprises a cutting machine generally shown at 110. The cutting machine 110 comprises a plurality of cutters 114. The cutters 114 are arranged in a spaced relation to the table 112. The cutters 114 are configured to cut a plurality of grooves in a second surface, opposite to the first surface, of the workpiece when the workpiece is supported on the table 112. For example, the second surface of the workpiece may comprise an upper or top surface 105 of workpiece 104. The plurality of grooves are cut in accordance with the cutting pattern defined for the workpiece. Each cutter of the plurality of cutters 114 is configured to cut a respective groove in the second surface 105 and the plurality of cutters 114 are controlled by the controller 106 to cut the grooves in an x-y-z coordinate system. In the x-y-z coordinate system an x-y plane is parallel to a surface of the table (which may be a top surface of the table, which top surface of the table is arranged to contact the first surface of the workpiece to support the workpiece) and a z-axis is orthogonal to the x-y plane. Grooves may also be referred to as slots or channels or the like.

[0027] In examples, a cutting pattern for the plurality of grooves may define one or more of: a number or quantity of grooves; distance between two or more adjacent grooves in the x direction; angle of one or more grooves relative to the y-direction; depth of one or more grooves.

[0028] Where reference is made to an x-direction or x-axis direction, this may be considered a direction along the x-axis or parallel to the x-axis. Where reference is made to a y-direction or y-axis direction, this may be considered a direction along the y-axis or parallel to the y-axis. Where reference is made to a z-direction or z-axis direction, this may be considered a direction along the z-axis or parallel to the z-axis.

[0029] In some examples, at least one cutter of the plurality of cutters 114 comprises a saw. In some examples, each and every cutter of the plurality of cutters 114 comprises a saw. The saw may comprise a rotary saw blade or saw disc. In some examples each of the saw blade(s) has or have a width of 1 .5mm (or about 1 .5mm).

[0030] It will nevertheless be appreciated that other types of cutters may be used. For example, one or more (or all of) the cutters of the plurality of cutters 114 may comprise any one of or any combination of, by way of non-limiting example: a hot wire cutter; a laser cutter; a plasma cutter; a milling head.

[0031] The cutting machine is configured such that a position in the x-axis direction of at least one cutter of the plurality of cutters 114 is controllable by the controller 106 relative to a position in the x-axis direction of another cutter of the plurality of cutters 114. This enables a spacing between at least two adjacent grooves of the plurality of grooves to be controlled. In other words, the cutting machine 102 is not constrained to fixed spacings in the x-direction between adjacent grooves. In some examples, one or more groove spacings in the x-direction may vary within a single workpiece. Or, groove spacings in the x-direction may be consistent within a single workpiece but varied for a subsequent workpiece.

[0032] According to some examples, the pitch or spacing between at least two adjacent grooves can be varied between 10 mm (or about 10mm) and 300 mm (or about 300mm). In some examples, groove spacings of greater than 300mm are possible.

[0033] The cutting machine 110 is configured such that a position in the z- direction of at least one cutter of the plurality of cutters 114 is controllable by the controller 106 to enable a depth of at least one groove to be controlled. In other words, the cutting machine 102 is not constrained to cut to fixed depths in the z-direction for the grooves. In some examples, one or more groove depths in the z-direction may vary within a single workpiece. Or, groove depths in the z-direction may be consistent within a single workpiece but varied for a subsequent workpiece. A depth of a groove may also be varied along a length of that groove.

[0034] According to some examples, the depth of at least one groove can be varied between 1 mm (or about 1 mm) and 100 mm (or about 100mm). According to some examples, a depth of the at least one groove may vary between 1 mm (or about 1 mm) and 100mm (or about 100mm).

[0035] According to some examples, a width of each groove may vary between 0.5mm (or about 0.5mm) and 10mm (or about 10mm). According to some examples, each groove has a width of 1 .5mm (or about 1 .5mm). Where the cutter is a saw blade, the width of the groove is dependent on the width of the saw blade. For example, a width of a saw blade may vary from 0.5mm to 10mm. In some examples, a saw blade may also be configured to cut a groove at an angle across the workpiece.

[0036] At least one of the cutting machine 110 and the table 112 is movable, relative to the other of the cutting machine 110 and the table 112, in the x-y plane or a plane parallel to the x-y plane, and in a direction either parallel to the y-axis or at an angle to the y-axis, for cutting the plurality of grooves across the surface of the workpiece 104. In some examples, the relative movement between the cutting machine 110 and the table 112 is or is about 1 m / s (60m / min), when positioning the cutting machine 110 and the table 112 relative to each other. During a groove cutting operation, the relative speed between cutting machine 110 and table 112 may be between 1 m / min and 15m / min (or between about 1 m / min and 15m / min).

[0037] In one example the cutting machine 110 and the table 112 are configured such that when the at least one of the cutting machine 110 and the table 112 are being moved relative to each other for cutting the plurality of grooves across the surface of the workpiece 104 the cutting machine 110 remains stationary while the table is moved. For example, the table may be configured to move at 1 m / s (or about 1 m / s). For example, the table 112 may be configured to move back and forth in the y-direction.

[0038] In one example the cutting machine 110 and the table are configured such that when the at least one of the cutting machine 110 and the table 112 are being moved relative to each other for cutting the plurality of grooves across the surface of the workpiece 104 the table 112 remains stationary while the cutting machine 110 is moved. For example, the cutting machine may be configured to move at 1 m / s (or about 1 m / s). For example, the cutting machine 110 may be configured to move back and forth in the y-direction or at an angle to the y-direction.

[0039] In one example the cutting machine 110 and the table 112 are configured such that when at least one of the cutting machine 110 and the table 112 are being moved relative to each other for cutting the plurality of grooves across the surface of the workpiece 104 both the table 112 and the cutting machine 110 are moved. For example, both the cutting machine 110 and the table 112 may be configured to move back and forth in the y-direction.

[0040] Of course, where it is said that the cutting machine 110 remains stationary this is referring to the overall body of the cutting machine 110, and does not preclude elements of the cutting machine 110 (such as a saw blade) from moving.

[0041] In some examples, the cutting machine 110 is mounted on at least one gantry 118 for supporting the cutting machine 110. The at least one gantry 118 extends in a longitudinal direction along a longitudinal axis of the gantry 118 that is parallel to the x-axis. In examples, the cutting machine 110 can reciprocate back and forth along the at least one gantry 118. In examples, the cutting machine 110 can reciprocate back and forth along the at least one gantry 118 along the longitudinal axis of the gantry 118 i.e. a direction parallel to the x-axis. This enables the cutting machine 110 to be moved between a variety of locations along the longitudinal axis of the gantry 118. In some examples, movement of the cutting machine 110 along the at least one gantry 118 is by a rack and pinion arrangement 152.

[0042] Figures 2 and 3 show an example of the cutting machine 110 in more detail. The cutting machine 110 comprises a first cutting machine assembly 116 mounted on a first gantry 118. The cutting machine 110 comprises a second cutting machine assembly 120 mounted on a second gantry 122. In other examples, only one cutting machine assembly is provided, for example only first cutting machine assembly 116 mounted on first gantry 118. In other examples, more than two cutting machine assemblies are provided, possibly with additional respective gantries. Movement of second cutting machine assembly 120 on second gantry 122 may be the same or similar to that of first cutting machine assembly 116 (or cutting machine 110 more generally) on gantry 118.

[0043] Therefore, it will be understood that first cutting machine assembly 116 can be moved between a variety of cutting locations along the longitudinal axis of the first gantry 118, and the second cutting machine assembly 120 can be moved between a variety of cutting locations along the second gantry 122.

[0044] In some examples the first cutting machine assembly 116 comprises a first cutting location at a first position 154 relative to first gantry 118, and a second cutting location at a second position 156 relative to first gantry 118. In some examples, the “first” and “second” cutting locations 154 and 156 need not be fixed and can be varied based on implementation and design requirements for a particular cutting pattern.

[0045] In some examples the second cutting machine assembly 120 comprises a first cutting location at a first position 158 relative to second gantry 122, and a second cutting location at a second position 160 relative to second gantry 122. In some examples, the first and second cutting locations 158 and 160 need not be fixed and can be varied based on implementation and design requirements for a particular cutting pattern.

[0046] In some examples, the first cutting location 154 of the first cutting machine assembly 116 is generally in front of the first cutting location 158 of the second cutting machine assembly 120. In some examples, an x co-ordinate of the first cutting location 154 of the first cutting machine assembly 116 is the same as an x- coordinate of the first cutting location 158 of the second cutting machine assembly 120. Note however that cutters on first cutting machine assembly 116 may be offset from cutters on second cutting machine assembly 120 in the x-direction, to provide groove spacings.

[0047] In some examples, the second cutting location 156 of the first cutting machine assembly 116 is generally in front of the second cutting location 160 of the second cutting machine assembly 120. In some examples, an x co-ordinate of the second cutting location of the first cutting machine assembly 116 is the same as an x- coordinate of the second cutting location of the second cutting machine assembly 120. Note however that cutters on first cutting machine assembly 116 may be offset from cutters on second cutting machine assembly 120 in the x-direction, to provide groove spacings.

[0048] In examples, the cutting machine 110 comprises a plurality of cutters. More specifically, in the example of Figure 3 each cutting machine assembly 116 and 120 comprises a plurality of cutters. In some examples, each cutting machine assembly 116, 120 comprises a plurality of cutter units or modules. In some examples, each cutter unit comprises a respective cutter.

[0049] For example, first cutting machine assembly 116 comprises cutter units 124, 126, 128 and 130. In this example, cutter units 124 and 126 are located on a front side (facing the table 112) of the gantry 118, and cutter units 128 and 130 are located on a reverse or rear side (facing away from the table 112) of the gantry 118. A cutter 132 is mounted on cutter unit 124, and a cutter 134 is mounted on cutter unit 126, and so on. The other cutter units have cutters attached thereto in a same or similar fashion.

[0050] In some examples, the position of each of the plurality of cutters is individually adjustable in the x-direction. For example, cutter 132 can be caused to reciprocate back and forth in the x-direction and cutter 134 can be caused to reciprocate back and forth in the x-direction.

[0051] In some examples, movement of each of the plurality of cutters 132, 134 is controlled by a respective servo-motor for enabling the position of the cutter to be individually adjustable in the x-direction. For example, a servo-motor 136 may control x-direction movement of cutter 132 and servo-motor 138 may control x-direction movement of cutter 134. The servo-motors enable fine and accurate motion control of the cutters in the x-direction.

[0052] In some examples, a position of each of the plurality of cutters is individually adjustable in the z-direction. For example, cutter 132 can be caused to reciprocate back and forth or up and down in the z-direction and cutter 134 can be caused to reciprocate back and forth or up and down in the z-direction.

[0053] In some examples, each of the plurality of cutters comprises a respective servo-motor for enabling the position of the cutter to be individually adjustable in the z-direction. For example, a servo-motor 140 may control z-direction movement of cutter 132 and servo-motor 142 may control z-direction movement of cutter 134. The servo-motors enable fine and accurate motion control of the cutters in the z-direction.

[0054] The same or similar concept applies to cutter units 128 and 130 as applies to cutter units 124 and 126.

[0055] Thus, in this example, cutting machine assembly 116 comprises four cutter units 124, 126, 128 and 130 each having a respective cutter, whose movement can be individually controlled in the x and y directions.

[0056] The same or similar concept applies to cutting machine assembly 120 as applies to cutting machine assembly 116. In summary, the cutting machine assembly 120 may comprise four cutting units 144, 146, 148 and 150. Each of the cutting units144 to 148 may comprise a respective cutter that is controllable in the x-direction by a respective servo-motor and in the z-direction by a respective servo-motor.

[0057] Thus overall, in one example, apparatus 102 comprises eight cutter units 124, 126, 128 ,130, 144, 146, 148 and 150 each having a respective cutter, the movement of each cutter being individually controllable in the x and z directions.

[0058] In examples, the at least one table 112 for supporting a workpiece comprises a first table 112 and a second table 113. The first table 112 has a home or rest position 111 , and the second table 113 has a home or rest position 115. In some examples, a y-coordinate of the rest position 111 of first table 112 is the same as a y-coordinate of the rest position 115 of the second table 113. The rest positions 111 and 115 of first and second tables 112 and 113 are located for easy access for an operator 101 , for example so that the operator can easily place workpieces on and remove workpieces from the first and second tables 112 and 113 respectively. In some examples, the rest position 111 of the first table 112 is adjacent to the rest position 115 of the second table 113, in the x-direction.

[0059] In some examples, the first table 112 is configured for supporting a first workpiece 104 and the second table 113 is configured for supporting a second workpiece 107. This means that the first and second workpieces 104, 107 can be worked on in a parallel or at least partially overlapping temporal manner. That is, the apparatus 102 comprising first and second tables 112, 113 may be considered a “pendular” machine.

[0060] Therefore, in some examples it may be considered that the at least one table 112 for supporting the workpiece comprises a first table 112 for supporting a first workpiece 104 and a second table 113 for supporting a second workpiece 107. In examples the first table 112 is configured to reciprocate back and forth in the y- direction so that the first table 112 can be selectively moved to the first cutting location of the first cutting machine assembly 116 or the first cutting location of the second cutting machine assembly 120. The second table 113 is configured to reciprocate back and forth in the y-direction so that the second table 113 can be selectively moved to the second cutting location of the first cutting machine assembly 116 or the second cutting location of the second cutting machine assembly 120.

[0061] In an example the first table 112 comprises a positioning arrangement shown schematically at 117, and second table 113 comprises a positioning arrangement shown schematically at 119. The positioning arrangements 117 and 119 provide aguide to the operator 101 as to where on the tables to position a respective workpiece. For example, each positioning arrangement 117, 119 may comprise one or more rails or protrusions that protrude from the table, up against which the operator 101 can push a corner or side of a workpiece. Additionally or alternatively the positioning arrangements 117, 119 may comprise markings on the tables 112, 113, such as one or more indicator lines. This enables positioning of a workpiece to be accurately framed or referenced, for subsequent correct alignment with the cutting machine 110.

[0062] In some examples a rack and pinion arrangement 162 enables the reciprocating movement of first table 112. In some examples a rack and pinion arrangement 164 enables the reciprocating movement of second table 114.

[0063] In some examples, the at least one table 112 (for example first and / or second tables 112 and 113) comprises a holding arrangement for securely holding a workpiece to the respective table. For example, the holding arrangement may comprise a vacuum or suction system for securely sucking the workpiece to the respective table. Alternatively the holding arrangement may comprise clips or the like to hold a periphery of the workpiece. The holding arrangement may be arranged to securely hold the workpiece to the table at least while the grooves are being cut in to the workpiece by the cutting machine 110.

[0064] According to examples the apparatus 102 comprises a conveyor system shown generally at 166. The conveyor system 166 comprises a first conveyor portion 168 for conveying a workpiece to an inlet area 170 of the apparatus 102. The inlet area 170 may be proximate to the table 112. The conveyor system 166 comprises a second conveyor portion 172 for conveying a workpiece away from the apparatus 102 after cutting by the cutting machine 110.

[0065] For further understanding, an exemplary method of cutting a plurality of grooves into two workpieces will now be described with respect to Figures 1 and 2. For the purpose of this example, it will be assumed that the apparatus 102 has been provided with the necessary numerical data defining the groove cutting patterns for each workpiece.

[0066] At least one of the workpieces is fed to the apparatus 102 along first portion 168 of conveyor 166. In this worked example, second workpiece 107 is fed in and placed on second table 113 by operator 101 . In some examples a support plate 123 is provided, which is movable up and down parallel to the z-axis, and which cansupport a workpiece. A workpiece can then be slid off the support plate 123 on to second table 113, which reduces lifting load for the operator 101. In some examples two such support plates are provided, one for each table 112, 113. The operator 101 may then initiate a groove cutting operation for second workpiece 107, for example via a user interface 174, or this process may automatically begin e.g. in response to a determination by controller 106 of workpiece 107 being placed on second table 113. For safety, in some examples the initiation of a cutting operation is a two-handed operation for the operator 101 to ensure that the operator cannot have their hands in the cutting machine during a groove cutting process. The cutting machines are then positioned appropriately. For example, cutting machine assembly 116 is moved to position such as position 156 or a similar position , and cutting machine assembly 120 is moved to position such as position 160 or similar, dependent on requirements. During a groove cutting operation the table 113, with workpiece 107 on top thereof, is then moved, in the y-direction and away from rest position 115 past the cutting machine assemblies 116 and 120 as the cutters are activated so as to cut grooves in the workpiece 107. In some examples, the cutting machine assemblies are activated sequentially, so that cutting machine assembly 120 is activated once cutting machine assembly 116 has completed its groove cutting operation (or vice versa in the reverse direction). Once the table has moved past the cutting machine assemblies 116 and 120, the position of the cutting machine assemblies 116 and 120 (and / or the position of cutters on the cutting machine assemblies), may be altered or adjusted. This positional adjustment may be in one or both of the x-axis or z-axis directions. In some examples this positional alteration can be relatively small. Then, once the cutters on the cutting machine assemblies 116 and 120 are activated or re-activated (together or sequentially), the table 113 is then moved, in the y-direction and towards rest position 115. Therefore, it may be considered that there are two “runs” of cuts made, a first run while the table 113 is moved away from rest position 115 and a second run while the table 113 is moved back towards rest position 115.

[0067] The process on first workpiece 104 on first table 112 can be the same or similar as the process described with respect to the second workpiece 107 on second table 113. In some examples, depending on how far in second table 113 is in its process, first table 112 may wait in the “out” or rest position 111. The first workpiece 104 is fed in and placed on first table 112 by operator 101. In someexamples, this may occur while the groove cutting operation is being performed on the second workpiece 107. The operator 101 may then initiate a groove cutting operation for first workpiece 104, for example via user interface 174, or this process may automatically begin e.g. in response to a determination by controller 106 of first workpiece 104 being placed on first table 112. The cutting machines are then positioned appropriately. For example, cutting machine assembly 116 is moved to position 154 or similar, and cutting machine assembly 120 is moved to position 158 or similar. During a groove cutting operation the first table 112 is then moved, in the y-direction and away from rest position 111 past the cutting machines as the cutters are activated so as to cut grooves in the first workpiece 104. Once the table has moved past the cutting machine assemblies 116 and 120, the position of the cutting machine assemblies 116 and 120 (and / or the position of cutters on the cutting machine arrangements), may be altered or adjusted. In some examples this positional alternation can be small. Then, once the cutters on the cutting machine assemblies 116 and 120 are activated or re-activated (together or sequentially), the table 112 is then moved, in the y-direction and towards rest position 111. Therefore, it may be considered that there are two “runs” of cuts made, a first run while the first table 112 is moved away from rest position 111 and a second run while the first table112 is moved back towards rest position 111.

[0068] In other words, for a groove cutting operation on either or both of the first and second workpieces, it may be considered that the apparatus is configured to cut a first set of grooves in a first run of the workpiece past the first and second cutting machines, and after an alteration to a position of the first and second cutting machines and / or an alteration of a position of at least one cutter of the first and second cutting machines, to cut a second set of grooves in a second run of the workpiece past the first and second cutting machines in a direction that is a reverse of the first run.

[0069] A completed groove cutting pattern for second workpiece 107 is schematically shown at 176. When the groove cutting operation for second workpiece 107 is completed according to the predetermined groove cutting pattern, and second table113 is returned to its rest position 115, the second workpiece 107 with completed groove cutting pattern 176 can then be placed on second conveyor portion 172 to be fed away from the apparatus 102.

[0070] At this point, a third workpiece (not shown) can be placed on now vacated second table 113 for groove cutting thereon.

[0071] Similarly, first table 112 is returned to its rest position 111 after the predetermined groove cutting pattern has been cut thereon, enabling the operator 101 to remove the first workpiece 104 from the first table 112 and place it on second conveyor portion 172 to be fed away from apparatus 102.

[0072] This process can continue in a continual or continuous manner.

[0073] It will of course be understood that this process has been described by way of example and that the order of certain steps may be changed. For example, a groove cutting pattern may be first carried out on first workpiece 104 on first table 112, followed by on second workpiece 107 on second table 113, in an otherwise same or similar manner to that described above. It will therefore be understood that the terms “first” and “second” with respect to the tables 112, 113 and workpieces 104, 107 is to aid with distinction between separate tables and workpieces for the purpose of clear understanding, and is not necessarily intended to imply a certain order to the process.

[0074] It may therefore be considered in some examples that there will (during operation) always be one table inside machine with a workpiece being processed while the other table is in the “out” or rest position.

[0075] In some examples, when one of the tables is in its rest position, the support plate for the other table moves up, so that a panel can be slid over it. For example, while first table 112 is in rest position 111 , support plate 123 is in its up position as shown in Figure 1 .

[0076] In some examples it may be considered that there is a safety area, which may comprise an area outside the cutting area where the tables 104, 113 are in their rest positions 111 , 115. In some examples a detector, such as a light beam, can be used to sense when a table is in the safety area.

[0077] By way of example and with reference to Figures 1 and 2, when the table 104 is in the out position or rest position 111 (i.e. in the safety area), and the support plate 123 is in the up or activated position, the safety area is de-activated. In this condition, the table 113 cannot move to its out or rest position 115, even if the cutting has finished. If this is the case the table 113 will wait in its operative position away from rest position 115, until the operator 101 activates the next cutting operation. Then, the safety area becomes active again.

[0078] A second embodiment will now be described with respect to Figures 4 to 6 which show an alternative arrangement for the apparatus. In Figures 4 to 6, features that correspond or at least closely correspond to the features of Figures 1 to 3 are given a like reference numeral except in 200 series.

[0079] As will be explained in more detail below, a difference between the first and second embodiments is that in the second embodiment an angular position of the cutting machine can be varied, enabling grooves to be cut that extend diagonally over the workpiece. For example, the cutting machine can be moved or drawn across the workpiece at an angle to the y-axis. Or, the cutting machine can be positioned at an angle and then remain stationary while the table is moved past the cutting machine.

[0080] As shown in Figures 4 and 5, the apparatus 202 comprises first and second gantries 218 and 222. The first and second gantries 218 and 222 support a third gantry 280. In some examples, the third gantry 280 is suspended from the first and second gantries 218 and 222. An operator is schematically shown at 201 .

[0081] A cutting machine 210 is supported on third gantry 280. In some examples, cutting machine 280 may be the same as or similar to first cutting machine assembly 116 described with respect to the first embodiment.

[0082] The third gantry 280 comprises a first attachment 288 for attaching the third gantry 280 to the first gantry 218, and a second attachment 290 for attaching the third gantry 280 to the second gantry 222. In some examples the first and second attachments 288, 290 comprise sliding wagons or carriages, so that the third gantry 280 is slidably mounted to the first and second gantries 218, 222. Accordingly a first end 279 of third gantry 280 can slide along first gantry 218, and a second end 281 of third gantry 280 can slide along second gantry 222.

[0083] In some examples a rotation mechanism 292 is attached to third gantry 280. In some examples the rotation mechanism comprises a triangular frame 294 which attaches to the second gantry 222. The triangular frame 294 also attaches to projection 280 which projects from third gantry 280. In some examples the projection 280 is mounted midway or approximately midway across the span of third gantry 280. The projection 280 thus acts as a centre of rotation or a pivot point 283 for the third gantry 280.

[0084] According to some examples, an angle a of the third gantry 280 relative to the y-axis is adjustable to enable cutting of the plurality of grooves across the surface of the workpiece at an angle to the y-axis.

[0085] According to some examples, the third gantry 280 is rotatable about the pivot point 283 between a range of angles relative to the y-axis. According to some examples the range of angles comprises a range between +60 degrees and -60 degrees. According to some examples the range of angles comprises a range between +45 degrees and -45 degrees.

[0086] According to some examples the cutting machine 210 can reciprocate back and forth along the third gantry 280, for example on a carriage 211 . In some examples the carriage 211 engages with the third gantry 280 via a rack and pinion system schematically shown at 221 .

[0087] In the example shown the apparatus 202 comprises first and second tables 212 and 213. These may function in the same or similar way as tables 112 and 113 described with respect to the first embodiment and therefore are not explained again in detail for conciseness. Nevertheless for completeness it is noted that first and second tables 212 and 213 can be driven towards and away from the cutting machine 210, to enable the pendular operation described with respect to the first embodiment, whereby multiple workpieces can be worked on in parallel or in an at least partially overlapping manner. For example first and second tables 212, 213 may be driven back and forth in the y-direction.

[0088] Similarly, apparatus 202 comprises a conveyor system 266 comprising a first conveyor portion 268 for conveying a workpiece to an inlet area 270 of the apparatus 202. The inlet area 270 may be proximate to the table 212. The conveyor system 266 comprises a second conveyor portion 272 for conveying a workpiece away from the apparatus 202 after cutting by the cutting machine 210.

[0089] A projector 296 is mounted on rail 295, enabling the projector to reciprocate back and forth in the x-direction along rail 295, for example via a rack and pinion system. The projector 296 can project information, such as a part number, on to a workpiece. This may assist the operator 201 in identifying a workpiece and / or can assist the operator 201 in cross-checking information on user interface 274. The projector 296 could also be incorporated into the first embodiment shown in Figures 1 to 3.

[0090] A framework 297 for the apparatus may also be provided. The framework 297 may, for example, support a cover or housing.

[0091] Figure 7 shows a housing 183. Although shown and primarily discussed with respect to the system 100 of Figures 1 to 3, it will be understood that the housing 183 could be equally applicable to the system 200 of Figures 4 to 6. The housing 183 acts to cover a substantial amount of apparatus 102. Particularly, the housing 183 acts to cover the cutting machine 110. In some examples, only authorised personnel have access to within the housing, for example via a lockable door or hatch. Moreover, the housing 183 acts to contain dust and particles that are produced as a result of the cutting process. In some examples, an extraction system 185 is provided for extracting dust and particles from the housing 183.

[0092] The apparatus 102 and 202 of system 100 and 200 are configured for cutting a groove pattern into workpieces of a variety of types, materials, shapes and dimensions.

[0093] For example, a workpiece may comprise a foam workpiece. The foam workpiece may comprise a polymer foam. In some examples, the foam workpiece is a polyethylene terephthalate (PET) foam workpiece.

[0094] In other examples, the workpiece may comprise a wooden material. For example, the workpiece may comprise balsa wood.

[0095] The shape of the workpiece is not limited. In some examples the workpiece is rectangular. In some examples the workpiece is square. In some examples the workpiece is provided in the form of a sheet. In some examples the maximum sheet size is or is about 1 .3m by 1 .4m. This may be the case where two tables are used in a pendular fashion, as previously described. In some examples the maximum sheet size is or is about 1 .3m by 2.8m. This may be the case where only one table is used, in a non-pendular fashion.

[0096] In some examples, a thickness of the workpiece varies between 10mm or about 10mm and 200mm or about 200mm. In some examples a thickness of the workpiece varies between 10mm or about 10mm and 80mm or about 80mm. In some examples, a maximum thickness of the workpiece is 80mm.

[0097] The density of the workpieces can be varied. For example, the density may vary between 50 kg / m3(or about 50 kg / m3) and 300 kg / m3(or about 300 kg / m3). In some examples the density may vary between 100 kg / m3(or about 100 kg / m3) and 275 kg / m3(or about 275 kg / m3).

[0098] In some examples at least one of the top or bottom surfaces of the workpiece is flat or planar. In some examples, both of the top and bottom surfaces of the workpiece are planar. In some examples at least one of the top or bottom surfaces is non-planar. In some examples, both of the top and bottom surfaces of the workpiece are non-planar. A non-planar surface may for example be corrugated or wavy, or have a saw-tooth profile.

[0099] It will be understood that the disclosure described herein enables a variety of groove cutting patterns to be cut into the surface of a workpiece. In examples, one or more of the following parameters can be controlled: depth of groove; spacing between adjacent grooves; length of groove; angle of groove across the workpiece. Moreover, by computer control of the moving or adjustable parts such as the tables and cutters, the apparatus can quickly switch between configurations for different grooving patterns. The apparatus does not necessarily require manual intervention, such as manual adjustment of the cutters by an operator, when switching between different grooving patterns.

[0100] The disclosure enables an increase in throughput of workpieces, compared to conventional systems for groove cutting. Where two (or more) tables and “pendular” motion (as previously described) is used, there can be zero or close to zero downtime. For example, while one workpiece is being subjected to groove cutting the next workpiece can be loaded, and so on.

[0101] By way of example, utilising the disclosure, it was found that it took 17.5 seconds to cut 8 grooves in a foam workpiece having a density of 115 kg / m3and a thickness of 30mm. It was also found that it took 25.5 seconds to cut 8 grooves in a foam workpiece having a density of 250 kg / m3and a thickness of 50mm.

[0102] In one comparative example, a full kit of core material panels (653 panels) for a wind turbine blade was subjected to groove pattern cutting. With a conventional CNC production machine comprising one sawblade, this took 14.5 hours. Using a grooving machine in accordance with the present disclosure, this time was reduced to 4.2 hours.

[0103] According to some examples the numerical data defining a cutting pattern is received from a computing apparatus, shown schematically at 300 in Figure 1 . The computing apparatus 300 is arranged to communicate with apparatus 102 or 202. More particularly, the computing apparatus 300 is arranged to communicate with controller 106 or 206. The computing apparatus 300 may be located on or proximateto the apparatus 102 or 202. Alternatively, the computing apparatus 300 may be located remote from the apparatus 102 or 202. The computing apparatus 300 hosts a software platform which enables design of one or more groove cutting patterns for one or more respective workpieces. In some examples, via the software platform an operator or engineer may manually design a groove cutting pattern to be cut in to one or more workpieces. In some examples, the software platform may compute a groove cutting pattern based on one or more input parameters. For example, input parameters for a wind turbine core kitting material or workpiece may comprise one or more of: geometrical fit; blade weight; resin uptake; manufacturing cost; panel weight; panel permeability; mechanical properties. The software may devise an optimum groove cutting pattern based on those one or more input parameters. An example of such a software platform is OptiCore™ by Gurit®. However the groove cutting pattern is generated, the computing apparatus 300 generates numerical data defining the cutting pattern, and transmits that numerical data to the controller 106 or 206.

[0104] It will be understood that the detailed description is exemplary, and that other embodiments are possible. For example, one or more features from the embodiments of Figures 1 to 3 and 7 may be combined with features from the embodiments of Figures 4 to 6 and vice versa, unless explained otherwise. The scope of the disclosure is not limited by the foregoing description, but is instead defined by the appended claims.

Claims

Claims1 . An apparatus for cutting a plurality of grooves in a workpiece, the apparatus being computer numerically controlled and configured to cut the plurality of grooves in accordance with information defining a cutting pattern, the apparatus comprising: a controller for receiving information comprising numerical data defining a cutting pattern for a workpiece; at least one table for supporting a first surface of a respective workpiece; and a cutting machine, comprising a plurality of cutters, the cutters arranged in spaced relation to the at least one table and configured to cut a plurality of grooves in a second surface, opposite to the first surface, of the workpiece when the workpiece is supported on the at least one table, the plurality of grooves being in accordance with the cutting pattern defined for the workpiece, wherein each cutter is configured to cut a respective groove in the second surface and the plurality of cutters are controlled by the controller to cut the grooves in an x-y-z coordinate system wherein an x-y plane is parallel to a surface of the at least one table and a z- axis is orthogonal to the x-y plane; wherein the cutting machine is configured such that a position in a direction parallel to the x-axis of at least one cutter of the plurality of cutters is controllable by the controller relative to a position in the direction parallel to the x-axis of another cutter of the plurality of cutters to enable a spacing between at least two adjacent grooves of the plurality of grooves to be controlled; wherein the cutting machine is configured such that a position in a direction parallel to the z-axis of at least one cutter of the plurality of cutters is controllable by the controller to enable a depth of at least one groove of the plurality of grooves to be controlled; and at least one of the cutting machine and the at least one table being movable, relative to the other of the cutting machine and the at least one table, in the x-y plane or a plane parallel to the x-y plane, and in a direction either parallel to the y-axis or at an angle to the y-axis, for cutting the plurality of grooves across the second surface of the workpiece.

2. The apparatus according to claim 1 , wherein the spacing between at least two adjacent grooves can be varied between 10 mm and 300 mm.

3. The apparatus according to claim 1 or claim 2, wherein the depth of at least one groove can be varied between 1 mm and 100 mm.

4. The apparatus according to any preceding claim, wherein the position of each of the plurality of cutters is individually adjustable in the direction parallel to the x-axis.

5. The apparatus according to claim 4, wherein each of the plurality of cutters comprises a respective first servo-motor for enabling the position to be individually adjustable in the direction parallel to the x-axis.

6. The apparatus according to any preceding claim, wherein a position of each of the plurality of cutters is individually adjustable in the direction parallel to the z- axis.

7. The apparatus according to claim 6, wherein each of the plurality of cutters comprises a respective second servo-motor for enabling the position to be individually adjustable in the direction parallel to the z-axis.

8. The apparatus according to any preceding claims, wherein the cutting machine and the at least one table are configured such that when the at least one of the cutting machine and the at least one table are being moved relative to each other for cutting the plurality of grooves across the surface of the workpiece, (i) the cutting machine remains stationary while the at least one table is moved; or (ii) the at least one table remains stationary while the cutting machine is moved; or (iii) both the at least one table and the cutting machine are moved.

9. The apparatus according to any preceding claim, comprising at least one gantry for supporting the cutting machine.

10. The apparatus according to claim 9, wherein the at least one gantry extends in a longitudinal direction that is parallel to the x-axis, the cutting machine configured to be moved back and forth along the longitudinal axis of the gantry.11 . The apparatus according to claim 9 or claim 10, wherein the cutting machine comprises a first cutting machine assembly and a second cutting machine assembly, the first cutting machine assembly being mounted on a first gantry and the second cutting machine assembly being mounted on a second gantry, each of the first and second gantries extending in a longitudinal direction that is parallel to the x-axis, the second gantry being mounted behind the first gantry in the y-direction, the first cutting machine assembly configured to be moved back and forth along the longitudinal direction of the first gantry between at least first and second cutting locations of the first cutting machine assembly, and the second cutting machine assembly being movable back and forth along the longitudinal direction of the second gantry between at least first and second cutting locations of the second cutting machine assembly.

12. The apparatus according to claim 11 , wherein the at least one table for supporting the workpiece comprises a first table for supporting a first workpiece and a second table for supporting a second workpiece, wherein the first table is configured to reciprocate back and forth in the y-direction so that the first table can be selectively moved to the first cutting location of the first cutting machine assembly or the first cutting location of the second cutting machine assembly, and the second table is configured to reciprocate back and forth in the y-direction so that the second table can be selectively moved to the second cutting location of the first cutting machine assembly or the second cutting location of the second cutting machine assembly.

13. The apparatus according to claim 11 or claim 12, wherein the apparatus is configured to cut a first set of grooves of the plurality of grooves in a first run of a respective workpiece past both the first and second cutting machines, and after an alteration to a position of the first and second cutting machines and / or an alteration of a position of at least one cutter of the first and second cutting machines, to cut a second set of grooves of the plurality of grooves in a second run of the respective workpiece past the first and second cutting machines in a direction that is a reverse of the first run.2214. The apparatus according to claim 9, wherein an angle of the gantry relative to the y-axis is adjustable to enable cutting the plurality of grooves across the surface of the workpiece at an angle to the y-axis.

15. The apparatus according to claim 14, wherein the gantry is rotatable about a pivot point between a range of angles relative to the y-axis.

16. The apparatus according to claim 15, wherein the range of angles comprises a range between +60 degrees and -60 degrees, and preferably the range of angles comprises a range between +45 degrees and -45 degrees.

17. The apparatus according to any preceding claim, comprising a conveyor system having a first conveyor portion for conveying workpieces to an inlet area of the apparatus prior to cutting by the cutting machine, and a second conveyor portion for conveying workpieces away from the apparatus after cutting by the cutting machine.

18. The apparatus according to any preceding claim, wherein the at least one table comprises a suction table for securely holding the workpiece on the at least one table.

19. The apparatus according to any preceding claim, wherein the plurality of cutters comprises two or more cutters, and preferably eight cutters.

20. The apparatus according to any preceding claim, wherein one or more of the cutters comprises a saw blade.21 . The apparatus according to any preceding claim, wherein one or more of the cutters comprises a hot wire; or a laser; or a milling head.

22. The apparatus according to any preceding claim, wherein the cutting machine is configured for cutting grooves in any one of: a foam workpiece; a polymer foam workpiece; a PET foam workpiece; a wooden workpiece; a balsa wood workpiece.

23. The apparatus according to any preceding claim, comprising a user interface for enabling an operative to control one or more parameters of the apparatus and / or for displaying information to the operative.

24. The apparatus according to any preceding claim, the apparatus in communication with a computing apparatus, and the apparatus configured to receive the numerical data defining a cutting pattern from the computing apparatus.

25. The apparatus according to any preceding claim, comprising a housing, and at least the cutting machine being located within the housing, and the housing comprising a ventilation system for extracting dust or particles from within the housing.

Images