Integrated toilet production line enabling the separate casting of toilet components and their assembly into a final product

Abstract

The invention relates to a toilet production line (10) for the manufacture of a toilet in which at least one rim part, at least one siphon part, and at least one outer shell part are separately manufactured and assembled. The novelty of the invention lies in comprising at least one rim casting machine (11), at least one siphon casting machine (12), and at least one outer shell casting machine (13) enabling the casting of the rim, siphon, and outer shell of the toilet; at least one adhesive unit used for assembling the parts produced in the casting machines by applying adhesive onto the parts; at least one resting unit for drying the produced parts; at least one conveyor line for transporting the final products out of the working area for transfer and cleaning; and a robotic arm (14) that transports the casting parts between the casting machines, adhesive unit, resting unit, conveyor line, and delivery rack and operates the entire system in an integrated manner.

Description

[0001] INTEGRATED TOILET PRODUCTION LINE ENABLING THE SEPARATE CASTING OF TOILET COMPONENTS AND THEIR ASSEMBLY INTO A FINAL PRODUCT

[0002] TECHNICAL FIELD

[0003] The invention relates to a toilet production line for the manufacture of a toilet in which at least one rim part, at least one siphon part, and at least one outer shell part are separately manufactured and assembled.

[0004] PRIOR ART

[0005] Toilet production is a process carried out by casting ceramic materials in liquid form into molds for shaping, followed by drying and assembly processes. In the current technique, the toilet is generally produced in two main parts: the body and the rim. The body includes the outer shell and the siphon region as an integrated whole. The rim is located at the upper part of the toilet and forms the area where the lid is seated. These two parts are joined by a single adhesive process to form the toilet. However, the single adhesive process used in this method leads to various technical difficulties during the production process. For example, producing the body as a single piece creates uncertainties in the production process and makes it difficult to resolve various issues.

[0006] In particular, since the body part includes both the outer shell and the inner siphon components, a problem occurring in this part can affect two different components simultaneously. Problems experienced in the body part require adjustments in both the outer shell and the siphon structure, and changes made in one component may result in positive outcomes while causing negative consequences in the other. For example, an improvement related to the outer shell may lead to deformations or durability issues in the siphon region. This situation creates complexity in the production process and adversely affects efficiency. Moreover, producing the bodyas a single piece complicates precise adhesive processes and causes durability and quality issues in the final product.

[0007] As a result, all the aforementioned problems have made it necessary to introduce an innovation in the relevant technical field.

[0008] BRIEF DESCRIPTION OF THE INVENTION

[0009] The present invention relates to a toilet production line aimed at eliminating the above-mentioned disadvantages and bringing new advantages to the relevant technical field.

[0010] An object of the invention is to provide a toilet production line that operates with high precision, is efficient, and focuses on automation.

[0011] Another object of the invention is to provide a toilet production line that minimizes errors in the production process, prevents time loss, and reduces costs.

[0012] To achieve all the objectives mentioned above and those that will emerge from the detailed description below, the present invention is a toilet production line for the manufacture of a toilet in which at least one rim part, at least one siphon part, and at least one outer shell part are separately manufactured and assembled. Accordingly, its novelty lies in comprising at least one rim casting machine, at least one siphon casting machine, and at least one outer shell casting machine enabling the casting of the rim, siphon, and outer shell of the toilet; at least one adhesive unit used for assembling the parts produced in the casting machines by applying adhesive onto the parts; at least one resting unit ensuring the drying of the produced parts; at least one conveyor line for transporting the final products out of the working area for transfer and cleaning; and a robotic arm that transports the casting parts between the casting machines, adhesive unit, resting unit, conveyor line, and delivery rack, and operates the entire system in an integrated manner.

[0013] A feature of a possible embodiment of the invention is that it includes a delivery rack for storing the produced toilets. Thus, the products are stacked in an orderlymanner, the risk of breakage or damage is reduced, and the logistics processes are facilitated.

[0014] Another feature of a possible embodiment of the invention is that it includes two rim casting machines, two siphon casting machines, and two outer shell casting machines, and the robotic arm is integrated with all of them simultaneously. In this way, waiting times in the production process are minimized, production capacity is increased, and the efficiency of the entire system is ensured.

[0015] Another feature of a possible embodiment of the invention is that it includes at least one manipulator for rotating the mold parts after the adhesive process. Thus, after molding is performed in the casting machines, rotation from the rim to the base can be achieved.

[0016] To achieve all the objectives mentioned above and those that will emerge from the detailed description below, the present invention is a production method for a toilet production line comprising at least one robotic arm, characterized in that the robotic arm takes the rim part from the rim casting machine, transports the rim part to at least one adhesive unit to ensure the application of adhesive material, transports the adhesive-applied rim part to the siphon casting machine and assembles it with the siphon part produced there, transports the assembled rim and siphon parts again to the adhesive unit to ensure the application of adhesive material for assembly with the outer shell, and transports the adhesive-applied rim and siphon assembly to the outer shell casting machine for assembly with the outer shell.

[0017] BRIEF DESCRIPTION OF THE DRAWING

[0018] Figure 1 presents a representative perspective view of the toilet production line of the invention.

[0019] Figure 2 presents a representative top view of the toilet production line of the invention.

[0020] DETAILED DESCRIPTION OF THE INVENTIONIn this detailed description, the subject matter of the invention is explained through examples intended solely to enhance understanding of the invention and without imposing any limiting effect.

[0021] Figure 1 presents a representative perspective view of the toilet production line (10) of the invention. Accordingly, the toilet production line (10) is an integrated line comprising casting machines that enable the separate casting of ceramic toilet components and a robotic arm (14) that assembles and transports these components. The toilet production line (10) of the invention includes separate casting machines for the three main components of the toilet — rim (upper region), siphon (internal structure), and outer shell (body) — and systems that assemble the components produced by these machines to form the final product. The toilet subject to this invention consists of three main sections: the rim, the siphon, and the outer shell. The rim is located at the upper part of the toilet and forms the area where the lid is seated and the flushing water is discharged. The siphon is a critical component forming the internal structure of the toilet and ensures the drainage of waste water, providing structural integrity by merging with the rim. The outer shell forms the external appearance of the toilet, holding the rim and siphon sections together and giving the product its final shape. These three sections are individually produced in the casting line and assembled to form a complete toilet in terms of aesthetics, durability, and functionality.

[0022] Figure 2 presents a representative top view of the toilet production line (10) of the invention. Accordingly, the toilet production line (10) includes at least one rim casting machine (11). The rim casting machine (11) is a system designed to produce the upper part of the toilet where the lid is seated. This rim casting machine (11) is designed to ensure the homogeneous distribution of ceramic material into the mold and to perform precise casting. The rim casting machine (11) comprises a casting group consisting of a lower plate, an upper plate, and uprights. The lower plate ensures that the ceramic material is fixed and the mold is securely supported during casting. The upper plate is moved by a piston group and completes the casting process by merging with the lower plate. This structure enhances the surface quality of the rim region and allows the product to bemanufactured with high precision. Additionally, the protective sheets and wear plates located on the uprights ensure the long-term operation of the system.

[0023] The robotic arm (14) transports the part produced in the rim casting machine (11) to at least one adhesive unit (not shown in the figures). After the necessary adhesive is applied in the adhesive unit, the rim part is used in the siphon casting machine (12) for the assembly process. Thanks to the precise movement capability of the robotic arm (14), the rim part is transported smoothly and prepared for the subsequent processes. This integration between the rim casting machine (11) and the robotic arm (14) ensures the uninterrupted operation of the production line.

[0024] The toilet production line (10) includes at least one siphon casting machine (12) following the rim casting machine (11). The mentioned siphon casting machine (12) is configured to produce the siphon region that constitutes the internal structure of the toilet. In this siphon casting machine (12), liquid ceramic material is injected between upper and lower molds, ensuring that the siphon region is produced with high precision. During the casting process, the molds remain in the closed position, and upon completion, the upper mold is lifted away from the lower mold into the open position. In the siphon casting machine (12), the side tables and transport assemblies used are elevated along with the upper mold as they move into the open position. In the open position, the rim part, which has been coated with adhesive, is placed onto the lower side of the siphon part, allowing them to be easily bonded together. After the casting process in the siphon casting machine (12) is completed, the robotic arm (14) picks up the rim part and combines it with the siphon part. During this process, the robotic arm (14) brings the adhesive applied to the rim part into contact with the siphon part at the adhesive unit and performs the assembly. The precise joining of the siphon and rim parts requires the robotic arm (14) to operate with high accuracy.

[0025] The toilet production line (10) includes at least one outer shell casting machine (13). The mentioned outer shell casting machine (13) is configured for the production of the body part that forms the outer surface of the toilet. This outer shell casting machine (13) distributes the ceramic mixture evenly into the mold to produce the outer shell part. During the casting process that takes place betweenthe lower and upper plates, proper alignment of the parts and tight closure of the molds are ensured. The outer shell casting machine (13) is supported by drive elements and piston groups, enabling the homogeneous distribution of the ceramic material within the mold. This structure enhances the surface quality of the product and enables the outer shell part to be brought into a suitable state for assembly.

[0026] The robotic arm (14) transports the rim and siphon assembly part obtained from the siphon casting machine (12) to the adhesive unit and enables the application of adhesive for its assembly with the outer shell. The robotic arm (14) then transports the adhesive-coated rim and siphon assembly part to the outer shell casting machine (13) and assembles it with the outer shell. At this stage, the task undertaken by the robotic arm (14) facilitates both the integration of the casting line and the acceleration of the final product's manufacturing process. This collaboration between the outer shell casting machine (13) and the robotic arm (14) enhances the efficiency of the production line.

[0027] The adhesive unit ensures the application of adhesive material necessary for the assembly of the casting parts. This adhesive unit applies adhesive to the rim, siphon, and outer shell parts transported by the robotic arm (14), making the parts suitable for the assembly process. The adhesive unit primarily uses adhesive casting slip and ensures that the adhesive is applied in the correct amount and on the correct surface. Additionally, the toilet production line (10) may include a manipulator (not shown in the figures). The mentioned manipulator can rotate the molded toilet into a usable position after molding. For example, the molded toilet can be positioned by rotating it from the rim onto the base before being discharged from the resting unit. In this way, the desired positioning for production is achieved.

[0028] The toilet production line (10) includes at least one resting unit (not shown in the figures). The mentioned resting unit is a holding system configured for the drying and hardening of the parts coming out of the casting process. The ceramic casting parts are placed on resting racks and kept there for a certain period. During this period, the ceramic material reaches the required durability and becomes suitable for subsequent processes. The resting unit ensures the orderly storage of the products and the optimization of the drying process. The robotic arm (14)transports the produced parts to the resting unit, initiating the next phase of the production cycle. The placement of the parts in the resting section and their retrieval after the resting period for transfer to the conveyor line are carried out by the robotic arm (14).

[0029] The toilet production line (10) includes at least one conveyor line (not shown in the figures). The mentioned conveyor line is configured for the parts that have completed the resting process, particularly to allow operators to clean excess material from the final product. The conveyor line enables the orderly transfer of products out of the working area and facilitates the transition to other stages of the production process. The conveyor line is equipped with light curtains and environmental sensors for safety purposes, forming a safety barrier between the area where the robotic arm (14) operates and the zones requiring human intervention. This structure contributes to the prevention of potential accidents during the production process. After the operator finishes processing the products transported on the conveyor line, the robotic arm (14) transfers them to at least one delivery rack.

[0030] The toilet production line (10) is integrated with the mentioned delivery rack (not shown in the figures). The delivery rack is a rack system configured for the storage of the final products completing the production line and for holding them in an orderly manner for subsequent processes. Storing the products on delivery racks enables the smooth progress of the production processes and facilitates logistics planning. The delivery racks have a durable structure that allows the products to be stored without the risk of breakage or damage. The robotic arm (14), which stacks the parts on the racks after receiving them from the resting unit or the conveyor line, also transports the parts back to the production line when needed.

[0031] The key element ensuring integration in the toilet production line (10) is the robotic arm (14). The robotic arm (14) ensures the transportation of parts among units such as the casting machines, adhesive unit, resting unit, conveyor line, and delivery rack. The robotic arm (14) possesses high accuracy and speed capabilities and undertakes the coordination of all processes within the casting line. This structure increases the efficiency of the toilet production line (10) and minimizes theneed for manual operations. The robotic arm (14) works in an integrated manner with two rim casting machines (11), two siphon casting machines (12), and two outer shell casting machines (13) simultaneously, thereby reducing waiting times. The robotic arm (14) operates in synchronization with each unit in the toilet production line (10), transporting the part taken from the rim casting machine (11) to the adhesive unit, and subsequently assembling the siphon and outer shell parts to form a complete toilet. The precise movement capability of the robotic arm (14) allows the parts to be transported to the correct positions safely. The ability of the robotic arm (14) to operate simultaneously with multiple casting machines reduces waiting times, increases production speed, and lowers costs. Moreover, it minimizes manual intervention, thereby preventing human-induced errors.

[0032] The scope of protection of the invention is defined in the claims provided in the annex and shall by no means be limited to the examples described in this detailed description. It is evident that a person skilled in the art may develop similar embodiments in light of the above explanations without departing from the main concept of the invention.REFERENCE NUMBERS GIVEN IN THE DRAWING

[0033] 10 Toilet Production Line

[0034] 11 Rim Casting Machine

[0035] 12 Siphon Casting Machine

[0036] 13 Outer Shell Casting Machine

[0037] 14 Robotic Arm

Claims

CLAIMS1. A toilet production line (10) for the manufacture of a toilet in which at least one rim part, at least one siphon part, and at least one outer shell part are separately manufactured and assembled, characterized in that it comprising at least one rim casting machine (11), at least one siphon casting machine (12), and at least one outer shell casting machine (13) enabling the casting of the rim, siphon, and outer shell of the toilet;at least one adhesive unit used for assembling the parts produced in the casting machines by applying adhesive onto the parts;at least one resting unit for drying the produced parts;at least one conveyor line for transporting the final products out of the working area for transfer and cleaning; anda robotic arm (14) that transports the casting parts between the casting machines, adhesive unit, resting unit, conveyor line, and delivery rack and operates the entire system in an integrated manner.

2. The toilet production line (10) according to Claim 1 , characterized in that it comprising a delivery rack for storing the produced toilets.

3. The toilet production line (10) according to Claim 1 , characterized in that it comprising two rim casting machines (11), two siphon casting machines (12), and two outer shell casting machines (13), and that the robotic arm (14) is simultaneously integrated with all of them.

4. The toilet production line (10) according to Claim 1 , characterized in that it comprising at least one manipulator for rotating the mold parts after the resting process.

5. A production method for a toilet production line (10) comprising at least one robotic arm (14), characterized in that the robotic arm takes the rim part from the rim casting machine (11 ),transports the rim part to at least one adhesive unit to ensure the application of adhesive material,transports the adhesive-applied rim part to the siphon casting machine (12) and assembles it with the siphon part produced there,transports the assembled rim and siphon parts again to the adhesive unit to ensure the application of adhesive material for assembly with the outer shell, and transports the adhesive-applied rim and siphon assembly to the outer shell casting machine (13) for assembly with the outer shell.

6. The production method for a toilet production line (10) according to Claim 4, characterized in that the final assembled toilet is transported to the resting unit by the robotic arm (14).

7. The production method for a toilet production line (10) according to Claim 5, characterized in that the toilet is transported by the robotic arm (14) to the conveyor line after the resting unit for final adjustments.

8. The production method for a toilet production line (10) according to Claim 6, characterized in that the toilet is transported by the robotic arm (14) and held on a delivery rack following the conveyor line.

Images