Marble Tile Cutting Machine with Horizontal Blade
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Solution Overview
Problem
Current methods for producing tiles from marble and granite require multiple machines, leading to inefficiencies in yield, quality, and material waste, with limitations in achieving thin tile thicknesses and automated surface processing, particularly for mosaic tiles smaller than 2 cm x 2 cm.
Innovation Solution
A single machine with adjustable cutting elements and a horizontal blade capable of cutting parallel to multiple axes, allowing for simultaneous horizontal and vertical cutting, and integrated pre-treatment options like oxy-hydrogen flames or polishing heads, enables the production of tiles with varying thicknesses and dimensions, including mosaic tiles, while minimizing material waste and enabling automated surface processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large vertical disc (about 1m diameter) is used to cut slabs, then the disc has sufficient stability and strength, but it produces economically unacceptable material loss (debris) when cutting slabs thinner than 3 cm
Solution Approach 1:
The cutting process is divided into multiple stages using different cutting elements: a first vertical disc for initial slab separation, followed by a second vertical disc for final thin slab cutting. This segmentation allows each disc to be optimized for its specific function, with the second disc being smaller and more suitable for precision cutting of thin slabs with minimal debris.
Solution Approach 2:
The invention introduces a horizontal cutting dimension by positioning the second vertical disc to cut slabs horizontally from the first slab, rather than vertically. This dimensional change enables precise control of slab thickness with minimal material waste, as the horizontal cutting plane can be accurately positioned close to the block surface.
2Ease of manufacture
If multiple separate machines are used for block cutting, splitting, and tile production, then each machine can be dedicated to a specific function, but the overall process becomes complex and less efficient
Solution Approach 1:
The invention combines multiple cutting functions (block cutting, slab splitting, and tile production) into a single integrated machine. The machine includes a first vertical disc for initial slab separation, a second vertical disc for thin slab cutting, and a horizontal blade for final tile detachment, all operating in sequence within one machine structure. This merging reduces device complexity while maintaining dedicated functions for each cutting stage.
Solution Approach 2:
The single machine is designed with multi-functional cutting elements that can perform different operations: the first vertical disc acts as a block cutter, the second vertical disc functions as a splitting tool for thin slabs, and the horizontal blade serves as a detachment tool for final tile separation. This universality allows one machine to replace multiple specialized machines, improving efficiency without sacrificing functional specialization.
3Extent of automation
If slabs are unloaded by robotic arm and turned 90°, then automation is achieved, but the likelihood of slab breakage significantly increases
Solution Approach 1:
The invention performs the final slab cutting to the exact required thickness before unloading, using the second vertical disc to create a precise cutting plane. This preliminary action ensures that slabs are already at their final dimensions and can be safely handled and unloaded without requiring subsequent breaking or splitting operations that would increase breakage risk.
Solution Approach 2:
Instead of cutting slabs to final thickness and then attempting to break them to achieve thinner sections (which causes breakage), the invention inverts the approach by using a horizontal blade to detach the final thin slab section from the block after vertical cutting. This reversal of the cutting sequence allows precise thickness control without mechanical breaking, maintaining slab integrity during automation.
4Manufacturing precision
If thin slabs (less than 3 cm) are produced, then tile thickness can be reduced, but the slabs become fragile and difficult to handle
Solution Approach 1:
The second vertical disc performs preliminary cutting of the slab to the exact final thickness required, creating a precise cutting plane that minimizes stress concentrations. This preliminary precision cutting allows the slab to maintain its strength even at thin dimensions, as the clean cut reduces edge defects that would otherwise weaken the slab.
Solution Approach 2:
The horizontal blade performs a partial cut through the block, detaching only the final thin slab section while leaving the main block intact. This partial action allows the thin slab to be supported by the remaining block during handling, providing excessive support that prevents breakage. The slab can be safely removed once the cut is complete, maintaining both thinness and strength.
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 machine optimizes tile production by allowing for thinner tile thicknesses, improved quality, and automated surface processing, reducing material waste and enabling the production of tiles that were previously difficult or impossible to achieve with existing technologies.
Implementation Method 1
a first set of first rotating cutting discs (D1, D2, ..., Dn, ...) arranged above said support surface and configured to cut said block parallel to said first horizontal line
Implementation Method 2
integrated pre-treatment options like oxy-hydrogen flames or polishing heads
Implementation Method 3
The machine may comprise pre-treatment means (9) for pre-treating the block (100), said pre-treatment means being an oxy-hydrogen flame
Data Source
Figure 1~2
Figure 3A~3B
Figure 4~5
AI summary
This invention relates to a machine (1 ) for producing tiles from a block (100), in particular a block (100) of marble, granite and the like, said machine (1 ) comprising a support surface (5') for supporting said block (100), said machine (1 ) being characterised in that it comprises a plurality of first cutting means (D1,..., Dn) for cutting said block (100) parallel to a first horizontal direction (X), said first cutting means (D1,..., Dn) being placed above said support surface (5'), comprising respective lower edges, configured to cut said block (100) on the upper part, said lower edges being placed at the same adjustable height, with reference to a vertical direction (Z), and being arranged aligned along at least a first horizontal axis (y'), parallel to a second horizontal line (Y), orthogonal to said first horizontal direction (X); in that said machine (1 ) comprises a second cutting means (E) for cutting said block (100) parallel to said second horizontal line (Y), said second cutting means (E) being configured to move along a second horizontal axis (y") relative to said support surface (5'), said second horizontal axis (y") being parallel or inclined with respect to said second horizontal line (Y) by a first angle a<90°, said second cutting means (E) having, during use, a resting position, wherein it does not interact with the block (100), and a working position, comprising a lower edge placed at said same adjustable height as said first cutting means (D1,..., Dn); in that said machine (1 ) comprises a horizontal blade (43) for cutting said block (100) along a horizontal plane, said horizontal blade (43) comprising a first cutting side (430) placed at said same adjustable height as said first cutting means (D1,..., Dn), and in that said support surface (5') is configured to move on said horizontal line (X) along a first cutting direction (X1 ), relative to said first cutting means (D1 Dn), to said second cutting means (E), and to said horizontal blade (43), said horizontal blade (43) being placed downstream of said first horizontal axis (y') and said second horizontal axis (y"), with reference to said first cutting direction (X1 ). This invention also relates to a method for cutting a block of marble and the like, into a plurality of tiles.