Robotic Veining for Stone and Ceramic Slabs with Color Control
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Solution Overview
Problem
Existing technologies for manufacturing slabs of conglomerate stone and/or ceramic material with a veined effect struggle to produce consistent veining of specific design, variable length, and width, and predefined color shading, as well as random dye distribution leading to unpredictable patterns.
Innovation Solution
A robot island equipped with multiple working heads and dispensing devices that form grooves and distribute color mixes with varying widths and colors, controlled by a programmable control unit, allowing for precise veining patterns and widths greater than previous methods, including grooves from 2 cm to 7 cm and 2 mm to 20 mm, with the use of color mixes containing binders to ensure consistency and differentiation from the base mix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If random dye distribution is used, then the process is simple, but the veined effect cannot achieve specific design patterns
Solution Approach 1:
The patent replaces manual/random mechanical dye distribution with an automated robotic system that uses programmable movement along Cartesian axes or anthropomorphic arms. The control unit directs the robotic arm to deposit dye at precise locations, transforming the random mechanical process into a controlled automated system that achieves specific veining patterns while maintaining operational simplicity through programming.
Solution Approach 2:
The robotic system automatically determines and executes the dye distribution pattern based on pre-programmed instructions stored in the control unit. The system serves itself by autonomously navigating the robotic arm along predetermined trajectories and controlling dye deposition without continuous human intervention, thereby achieving precise veining patterns while reducing the need for complex real-time human control.
2Adaptability or versatility
If fixed vein width is used, then the manufacturing process is simple, but variable length veining and stain-like patterns cannot be formed
Solution Approach 1:
The patent implements dynamic control of the robotic arm's movement and dye deposition rate. The system can vary the speed, position, and amount of dye deposited at different locations along the slab, enabling the formation of veins with variable lengths and widths. This dynamic capability allows the creation of diverse patterns including stain-like effects while the programmable nature maintains manufacturing simplicity through software control.
Solution Approach 2:
The system changes multiple parameters including robotic arm position, dye flow rate, and deposition timing to achieve variable vein characteristics. By programmatically adjusting these parameters during the dyeing process, the system can create veins of different lengths, widths, and intensities, as well as stain-like patterns, without requiring physical changes to the equipment structure.
3Adaptability or versatility
If small vein widths are used, then the detail precision is high, but large width veining cannot be achieved
Solution Approach 1:
The robotic system dynamically adjusts the dye deposition parameters based on the desired vein width. For narrow veins, the system uses precise positioning with slow movement and controlled dye flow. For wide veins, the system increases movement speed and dye deposition rate while maintaining trajectory accuracy. This dynamic parameter adjustment enables the single robotic system to handle the full range from 2mm to 20cm vein widths while preserving precision through programmable control.
Data Source
AI summary
Method for manufacturing automatically slabs of conglomerate stone and/or ceramic material with a veined effect from a base mix (M), which method comprises a step of a) depositing a layer of base mix (M) inside a temporary support (S), (b) automatically forming on the layer of base mix (M) at least one plurality of grooves (F) of predetermined width, c) automatically distributing at least one dye inside the grooves (F) and d) compacting the layer of base mix (F). The at least one dye consists of a colouring mix (C1, C2) comprising at least one binder. The invention also relates to a robot island (1) for forming veining in a layer of base mix (M) for the manufacture of slabs and an apparatus for manufacturing slabs with a veined effect.