Integrated Cutting Head for One-Pass Slab Chamfering
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Solution Overview
Problem
Current stone and ceramic processing machine tools face inefficiencies in cutting and chamfering operations due to complex blade installation, misalignment issues, and high maintenance costs, leading to increased processing times and reduced throughput.
Innovation Solution
A cutting and chamfering head with vertically aligned blades and a grinding wheel, adjustable for relative height, allowing for simultaneous cutting and chamfering in a single pass, reducing processing times and eliminating the need for skilled operator handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single cutting blade is used for both cutting and chamfering operations, then the device complexity is reduced, but the productivity decreases due to multiple processing steps
Solution Approach 1:
The patent combines multiple cutting blades (first cutting blade and second cutting blade) and a chamfering disk into a single integrated cutting head assembly. This merging of components allows simultaneous execution of cutting and chamfering operations, resolving the contradiction by maintaining low device complexity while achieving high productivity through parallel processing.
Solution Approach 2:
The cutting head is designed as a universal assembly that can perform multiple functions: the first cutting blade creates a precut, the second cutting blade completes the cut, and the chamfering disk creates chamfers. This multi-functionality enables a single device to handle both cutting and chamfering operations, eliminating the need for separate processing steps and improving productivity without increasing overall system complexity.
2Manufacturing precision
If the cutting blade and chamfering disk are separated and repositioned, then the manufacturing precision can be adjusted, but the loss of time increases due to stopping and repositioning
Solution Approach 1:
The cutting blades and chamfering disk are pre-aligned and fixed in predetermined positions within the cutting head assembly during manufacturing. This preliminary action ensures that when the cutting head is installed, all components are already in their correct positions, eliminating the need for time-consuming stopping, lifting, and repositioning operations while maintaining high alignment precision.
Solution Approach 2:
By merging the cutting blades and chamfering disk into a single integrated assembly with fixed relative positions, the patent eliminates the time loss associated with separating and repositioning components. The unified structure ensures that cutting and chamfering operations can be performed in sequence without interrupting the machine operation, thus resolving the contradiction between precision and time loss.
3Adaptability or versatility
If multiple cutting blades with different diameters are used, then the adaptability increases for different slab thicknesses, but the device complexity increases
Solution Approach 1:
The patent incorporates adjustable height mechanisms that allow the cutting blades and chamfering disk to be dynamically positioned at different vertical levels. This dynamic adjustability provides versatility for processing slabs of different thicknesses without requiring multiple blades of different diameters, thus achieving adaptability while maintaining relatively simple device structure.
Solution Approach 2:
Instead of changing the diameter of cutting blades to adapt to different slab thicknesses, the patent changes the vertical position parameter of the cutting blades and chamfering disk through height adjustment mechanisms. This parameter change approach provides the same adaptability with simpler device complexity, as adjusting height is mechanically simpler than replacing or reconfiguring blades of different diameters.
4Productivity
If additional cutting blades are installed to increase productivity, then the productivity improves, but the ease of operation deteriorates due to difficult installation and alignment
Solution Approach 1:
The patent merges multiple cutting blades and a chamfering disk into a single pre-assembled cutting head unit. This merging simplifies installation and operation because the entire multi-component assembly is installed as one unit rather than individually installing and aligning each blade and disk. The pre-assembly ensures correct relative positioning, making the system easy to operate while maintaining high productivity through multiple simultaneous cutting functions.
Solution Approach 2:
The cutting blades and chamfering disk are pre-aligned and secured in their correct positions during the manufacturing of the cutting head assembly. This preliminary action eliminates the need for complex field alignment operations, making installation straightforward and operation easy while enabling high productivity through the coordinated action of multiple blades.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces slab cutting and chamfering times, increases machine throughput, and simplifies installation and maintenance, enabling cost-effective and efficient processing without requiring specialized operator skills.
Implementation Method 1
a first blade (12) making a precut (T1) on the slab (L)
Implementation Method 2
at least one grinding wheel (14), which is mounted to the frame (11) to create a chamfer (G) along a cutting line (C)
Implementation Method 3
a second blade (13) making a cut (T2) on the slab (L)
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A cutting and chamfering head (1) for use in a multiaxial machine tool (2) for processing stone and/or ceramic slabs (L), the head (1) comprising a carriage (9) that is designed to move over the slab (L) along a first transverse axis (X2) and a second longitudinal axis (X1) by means of first (4) and second (6) guide means. The head comprises a tool-holding frame (11) mounted to the carriage (9) and supporting at least one first blade (12) and one second blade (13) which are substantially vertical, substantially aligned and vertically offset from each other so that the first blade (12) will make the precut and the second blade (13) will make the final cut of the slab (L), or vice versa, and also at least one grinding wheel (14) mounted to the frame (11) to create a chamfer (G) along a cutting line (C) substantially aligned with the first blade (12) and the second blade (13), the blades (12, 13) and the grinding wheel (14) being configured to cut and chamfer the slab (L) in one pass. A multiaxial machine tool (2) for processing stone or ceramic slabs (L), which comprises such cutting and chamfering head (1) and a method of cutting and chamfering a slab (L) using one or more cutting and chamfering heads (1).