BLADE GRINDING SYSTEMS AND METHODS

FIELD

This disclosure is directed to blades for tufting apparatuses and, in particular, to grinding said blades when held within a blade block.

BACKGROUND

Tufting apparatuses have a plurality of tufting blades that are held within a blade block. The tufting blades are configured to cut yarns of tufted articles. The tufting blades must be sharpened periodically. Conventionally, the tufting blades are removed from the blade block, and the tufting blades are then sharpened individually. This process is slow, costly, labor intensive, and subject to human error. Accordingly, an automated process that reduces one or more of operator interaction, time, or human error is desirable.

SUMMARY

Disclosed herein is a method of grinding a plurality of tufting blades of a blade assembly. The plurality of tufting blades can be received within a blade block during grinding. The blade assembly can have a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes. Each tufting blade of the plurality of tufting blades can have a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis. The plurality of tufting blades can be spaced from each other along the third axis. The blade assembly can comprise at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block.

Also disclosed herein is a system for grinding blade assemblies. The system can comprise a blade assembly. The blade assembly can comprise a plurality of tufting blades received within a blade block. The blade assembly can have a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes. Each tufting blade of the plurality of tufting blades can have a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis. The plurality of tufting blades can be spaced from each other along the third axis. The blade assembly can comprise at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block. The system can further comprise a fixture that is configured to hold the blade assembly and a grinder that is configured to grind the tufting blades of the blade assembly held within the fixture.

Additional advantages of the disclosed system and method will be set forth in part in the description which follows, and in part will be understood from the description, or may be learned by practice of the disclosed system and method. The advantages of the disclosed system and method will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a blade assembly comprising a plurality of tufting blades held within a blade block in a use configuration.

FIG. 2 is a perspective view of a plurality of blade assemblies as in FIG. 1 held within a fixture for grinding.

FIG. 3A is a schematic diagram of a blade block and grinding wheel looking along a grinding wheel movement axis, illustrating the formation of the blade angle. FIG. 3B is a schematic diagram of the blade block and grinding wheel looking perpendicular to the grinding wheel movement axis, showing the formation of a relief angle.

FIG. 4 is a perspective view of a first blade alignment assembly for positioning the tufting blades relative to the blade block.

FIG. 5 is a perspective view of a blade assembly comprising a plurality of tufting blades held within a blade block in a grinding configuration.

FIG. 6 is a bird’s eye view of a system for grinding blade assemblies as disclosed herein.

FIG. 7 is a perspective view of tray holding a plurality of a blade assemblies as in FIG. 1.

FIG. 8 is a rear perspective view of the system as in FIG. 6.

FIG. 9 is a front perspective view of the system as in FIG. 6.

FIG. 10A is a first perspective view of a second end of arm tool of the system of FIG. 6, depicting the tool loading blade assemblies into a fixture. FIG. 10B is a perspective view of the second end of arm tool while gripping a pair of fixtures holding blade assemblies. FIG. 10C is a perspective view of the second end of arm tool while moving along a rail toward a grinder. FIG. 10D is a perspective view of the second end of arm tool while holding a pair of fixtures holding un-ground blade assemblies and positioning itself for gripping a pair of fixtures holding ground blade assemblies. FIG. 10E is a perspective view of the second end of arm tool while rotating to position the fixtures holding un-ground blade assemblies for placement in the grinder. FIG. 10F is a perspective view of the second end of arm tool while placing the fixtures holding un-ground blade assemblies in the grinder. FIG. 10G shows a detail perspective view of the second end of arm tool placing blade assemblies in a fixture.

FIG. 11 is a perspective view of a second blade alignment assembly for positioning the tufting blades relative to the blade block.

FIG. 12 is another perspective view of the first blade alignment assembly of FIG. 4 for positioning the tufting blades relative to the blade block.

FIG. 13A is a perspective view of the first end of arm tool and a portion of the system of FIG. 6. FIG. 13B is another perspective view of the first end of arm tool and a portion of the system of FIG. 6. FIG. 13C shows a detail perspective view of the first end of arm tool. FIG. 13D shows a perspective view of a cleaning station. FIG. 13E shows a perspective view of a deburring station. FIG. 13F shows a partial perspective view of the system including post-grinding stations such as a cleaning station, a printing station, a visual inspection station, and a third robotic arm for handling ground blade assemblies. FIG. 13F shows the first end of arm tool separate from the first robotic arm in a plurality of different positions at the visual inspection station.

FIG. 14 is a schematic diagram of a system network for communicating between various components of the system of FIG. 6.

FIG. 15 is a block diagram of control system comprising a computing device as disclosed herein.

DETAILED DESCRIPTION

The disclosed articles, systems and methods may be understood more readily by reference to the following detailed description of particular embodiments and the examples included therein and to the Figures and their previous and following description.

It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present disclosure which will be limited only by the appended claims.

It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a blade block” includes one or more of such blade blocks, and so forth.

“Optional” or “optionally” means that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present.

Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, also specifically contemplated and considered disclosed is the range from the one particular value and/or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherwise. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and sub-ranges of values contained within an explicitly disclosed range are also specifically contemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these embodiments are explicitly disclosed.

Optionally, in some aspects, when values are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.

Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed apparatus, system, and method belong. Although any apparatus, systems, and methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present apparatus, system, and method, the particularly useful methods, devices, systems, and materials are as described.

Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of”), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step.

It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification. Thus, words denoting order, such as “first” or “next,” should be interpreted as optional aspects unless plain meaning or logic dictates otherwise.

Disclosed herein and with reference to FIGS. 6, 8, and 9 is a system 100 for grinding tufting blades of blade assemblies. Referring to FIGS. 1-5, a blade assembly 10 can comprise a blade block 12 and a plurality of tufting blades 14 (or “blades” as used interchangeably herein) received within the blade block. The blade assembly 10 can have a first axis 16, a second axis 18 that is parallel to the first axis, and a third axis 20 that is perpendicular to each of the first and second axes. The tufting blades 14 can be spaced along the third axis 20 relative to each other. Each of the tufting blades 14 can define a blade edge 22 at a first longitudinal end 24. The blade assembly 10 can comprise one or more fasteners 26 that are configured to retain the plurality of tufting blades 14 in respective fixed positions relative to the blade block 12 along the first axis 16. The fastener(s) 26 can comprise, for example, one or more screws (e.g., four set screws, as shown). In yet further aspects, the fastener(s) 26 can comprise a clamp, one or more locking pins, a latch, combinations thereof, and the like. The fastener(s) 26 can be loosened to allow the tufting blades 14 to slide along the first axis 16 for repositioning the tufting blades relative to the blade block 12 or removal from the blade block. The fastener(s) 26 can then be tightened to fix the blades axially relative to the blade block 12 along the first axis 16. The blade block 12 can be configured for mounting to a tufting machine for use. As is known, in use, tufting blades are mounted to the tufting machine as blade assemblies 10.

A grinder 28 can be configured to grind the tufting blades 14 with the tufting blades received within the blade block 12. A fixture 30 can be configured to hold one or more blade assemblies as the grinder 28 grinds the tufting blades. In exemplary aspects, the fixture 30 can hold a single blade block. In other aspects, the fixture can hold two, three, four, five, six, or more blade blocks. The fixture 30 can hold the blade assemblies 10 in a particular orientation relative to a grinding element (e.g., a grinding wheel 29) of the grinder 28 in order to form a particular profile, such as, for example, a predetermined cutting angle and, optionally, a predetermined relief angle at the blade edge 22.

In exemplary aspects, the grinder 28 can comprise a grinding wheel 29 that is configured to rotate about a rotational axis. The grinder 28 can further comprise a plurality of actuators (e.g., linear actuators) that are configured to control the position of the grinding wheel 29 along x, y, and z axes (e.g., first and second perpendicular horizontal axes and a vertical axis) and an actuator (e.g., a motor) for imparting rotational movement of the grinding wheel. For example, the grinder 28 can be a computer numerical control (CNC) grinder that can have programmable control of rotation speed, position and linear movement speed of the grinding wheel. In various exemplary aspects, the grinder can be a 5-axis CNC grinder. In exemplary aspects, the grinder 28 can be a commercially available CNC grinder, such as a WELDON CNC grinder provided by Weldon Solutions of York, PA.

Blade Alignment for Grinding

Referring to FIGS. 3A-4, a first blade alignment assembly 40 can be configured to position each tufting blade 14 of the plurality of tufting blades relative to the blade block 12 along the first axis 16 in a grinding configuration prior to grinding. For example, it is contemplated that the blades can advantageously be ground with the blade edges 22 positioned close to the blade block (e.g., no more than 30 mm, no more than 20 mm, no more than 15 mm, or no more than 10 mm from the blade block). Further, the blade edges 22 can be axially staggered relative to each other along the third axis 20, extending different distances from the blade block along the first axis 16. For example, a first blade 12a at a first end 13 of the blade assembly 10 along the third axis 20 can extend from the blade block by a first distance, and each sequential blade along the third axis 20 can be incrementally spaced by a greater distance (e.g., optionally, by the same increment) than the first distance. It is contemplated that this spacing can, in conjunction with an angle at which the blade block is held relative to the grinding element, form a predetermined blade angle. As shown in FIG. 3A, the predetermined blade angle can correspond to θ1, an angle that the top edges of the blades make relative to the third axis 20 of the blade block. The predetermined blade angle can be, for example, from about 15 to about 60 degrees, or from about 20 to about 45 degrees, or about 22 degrees.

Referring to FIGS. 4 and 12, the first blade alignment assembly 40 can comprise a first linear actuator 42 that is coupled to a first guide 44. In some optional aspects, the first blade alignment assembly 40 can further comprise a second linear actuator 46 that is coupled to a second guide 48. The first actuator 42 can be configured to move the first guide 44 in a first direction to shift the blade edges 22 of the tufting blades 14 outwardly from the blade block 12 along the first axis 16. The second actuator 46 can then move the second guide 48 against the tufting blades 14 to position the tufting blades 14 in their proper grinding configuration (FIG. 1), with each tufting blade positioned at its respective position extending the predetermined distance from the blade block 12 along the first axis. The second guide 48 can define a surface 50 (e.g., a planar profile or a stepped profile) that defines the spaced relationship between the blade block 12 and each of the tufting blades along the first axis 16 (e.g., the incremental distances between the tufting blades). Optionally, the first actuator 42 and first guide 44 can be omitted.

The system can comprise a device for disengaging the fastener(s) 26 to permit movement of the tufting blades relative to the blade block and for manipulating the fastener(s) to secure (e.g., retain) the plurality of tufting blades relative to the blade block. For example, a driver 52 (e.g., a torque screwdriver) can loosen the fastener(s) prior to engagement of the first blade alignment assembly 40 to enable movement of the tufting blades 14 relative to the blade block 12. The driver 52 can then tighten the fastener(s) after the first blade alignment assembly 40 positions the tufting blades 14 for grinding. The driver 52 can torque the fasteners to a predetermined torque. The device for disengaging and engaging the fastener(s) 26 can be configured for the particular type of fastener. Thus, for example, for a fastener comprising a locking clamp, the device for disengaging and engaging the fastener(s) 26 can comprise an arm that actuates (e.g., effects movement of) the locking clamp about and between a disengaged condition and an engaged condition.

Receipt and Pre-Grinding Processing of Blade Assemblies

The system 100 can receive a plurality of blade assemblies 10 positioned within a tray 54. The tray 54 can define one or more receptacles that maintain the plurality of blade assemblies 10 in a predetermined orientation and spaced relationship relative to each other. The tray 54 can comprise an identifier that is associated with at least one parameter of the plurality of blade assemblies therein. That is, the identifier can indicate what blade assemblies 10 are placed therein. For example, different blade assemblies 10 can be configured for different machines or otherwise associated with particular inventories (e.g., particular plants or locations within a plant). Thus, it can be advantageous to identify the blade assemblies 10 within the tray 54. Optionally, the identifier can be a color. For example, the tray, or a portion of the tray (e.g., a stripe 55) can have a color associated with a particular grouping of blade assemblies (e.g., blade assemblies configured for a particular tufting machine). In some aspects, the identifier can comprise a symbol or an alphanumeric identification or a combination thereof. In further aspects, the identifier can be a machine-readable identifier, such as, for example, an optical or electronically readable identifier, such as, for example, a barcode, a QR code, a scannable tag, a recognizable image, combinations thereof, and the like.

Referring to FIGS. 6, 13A, and 13B, the system 100 can comprise a first conveyor 60 that is configured to receive a plurality of blade assembles 10 in a tray 54. The first conveyor 60 can be, for example, a belt or roller conveyor. The system 100 can further comprise a second conveyor 62 that is configured to move the blade assembles 10 about and between one or more processing stations. For example, the second conveyor 62 can comprise a transfer pallet 70 that is configured to hold a plurality of (e.g., four) blade assemblies 10. Optionally, the trays 54 can be stacked. For example, the trays can be stacked in a plurality of layers (e.g., six layers high) on the first conveyor 60.

The system 100 can comprise a first end of arm tool 64 that is configured to receive the blade assemblies 10 from the first conveyor 60 (e.g., from the tray 54) and transfer the blade assemblies to the second conveyor 62. The end of arm tool 64 can be coupled to a robotic arm 65, such as, for example, a six- or seven-axis robotic arm. The end of arm tool 64 can comprise a suction gripper, a clamp, or any suitable tool for lifting and releasing the blade assemblies 10. The first end of arm tool 64 can further be configured to grip and move the tray 54. In this way, the first end of arm tool 64 can move empty trays 54 to allow for subsequent trays 54 to advance for unloading.

Optionally, the first end of arm tool 64 can position each blade assembly 10 at a visual inspection assembly 66. The visual inspection assembly 66 can comprise an optical sensor or scanner (e.g., a camera, a laser scanner, or other machine vision system) that can detect one or more attributes of the blade assembly 10. The one or more attributes can comprise, for example, number of blades, a shortest blade length, a roughness of blades, or a combination thereof. The optical sensor or scanner can be in communication with one or more processors to analyze data from the optical sensor or scanner. The processor(s) can optionally be part of the visual inspection assembly 66 or in electrical communication therewith. The processor(s) can be in communication with memory for performing routines to analyze the attributes of the blade assembly 10. In exemplary aspects, the processor(s) and memory can be embodied as the processor 1003 and mass storage device 1004 of the computing device 1001 as further described herein with reference to FIG. 15. For example, the processor 1003 can be configured to determine if the blade assembly 10 has the correct number of tufting blades 14 (or if any of the blades are broken). The processor 1003 can further be configured to determine whether all of the blades have a sufficient length for grinding and reuse. For example, the processor can determine, based on the optical sensor or scanner (e.g., camera) the length of each of the blades, and the processor can further compare the length of each of the blades (or the shortest blade) to a minimum threshold. If the processor 1003 determines that blade assembly 10 has all necessary tufting blades 14 and the blades are of sufficient length for grinding and reuse, the blade assembly 10 can be moved to the transfer pallet 70 of the second conveyor 62. The visual inspection assembly 66 can further be configured to determine blade thickness and the hand/orientation (e.g., left-handed or right-handed) of blades in the block.

If the blade assembly 10 does not have enough tufting blades 14, or if the blades are too short for grinding and reuse, the blade assembly 10 can be moved to a rejection station. The rejection station can be a receptacle (e.g., a tray, bucket, etc.) that can receive rejected blade assemblies 10. Optionally, the end of arm tool 64 can replace the rejected blade assembly with a makeup blade assembly from a makeup assembly supply. For example, the end of arm tool 64 can move the makeup blade assembly from the makeup assembly supply to the transfer pallet 70 of the second conveyor 62.

In some aspects, the rejection station can comprise a reloading station. In some optional aspects, the reloading station can be operated manually. For example, an operator can remove any blades that are too short or otherwise unusable and add blades to replace removed or omitted blades. In other aspects, an automated station can be configured to determine, based, for example, on data from the visual inspection assembly 66, which blades are missing and/or need to be replaced, and the reloading station can comprise a supply of usable (e.g., new) blades, an end of arm tool for removing spent blades and positioning the usable blades within the blade block. The reloading station can further comprise a driver for loosening the fastener(s) 26 for release of the spent blades and tightening the fastener for securing the blades within the blade block.

In some aspects, the visual inspection assembly 66, via the processor 1003, can further be configured to classify the roughness of the blade assembly based on the roughest tufting blade of the plurality of tufting blades in order to determine the necessary amount of grinding to provide refurbished, even blades. For example, the visual inspection assembly 66 can be configured to classify the blades as “mild wear,” “moderate wear,” or “severe wear.” The classification can be associated with the worst blade of the plurality of blades (i.e., the blade requiring the most grinding to be in refurbished condition) and can correspond to or correlate with a length of blade needed to be ground from the worst tufting blade to put said tufting blade in refurbished condition (e.g., with a straight edge 22). A predetermined length can be removed from each blade during grinding based on the classification. Lesser amounts of wear can be associated with lesser amounts of grinding, and larger amounts of wear can be associated with relatively more grinding. Thus, the amount of grinding can be proportional to the wear of the blades. For example, mild wear can be associated with one millimeter of blade grinding (across all blades), moderate wear can be associated with two millimeters of blade grinding, and severe wear can be associated with three millimeters of blade grinding. Other amounts of blade grinding can be selected for each category depending on user specifications. Similarly, it is contemplated that more or less than the stated classifications of wear can be employed within the system as desired. For example, it is contemplated that the system can be configured to classify the blades as “low wear” or “high wear.”

In some optional aspects, roughness can be quantified as a maximum variation in the edge of the blade surface along the first axis 16, when moving along the edge of the blade surface across the second axis 18. For example, chips in the blade can cause wear or chips or wear that lead to variation of the edge of the blade surface across the second axis 18. The variation can be measured as a distance (e.g., measured in millimeters) along the axis 16. The measured distance of variation can be compared to one or more thresholds in order to classify the wear of the blades. For example, using the example above, the threshold between mild and moderate wear can be 1 millimeter. Thus, moving across the blade surface a measured variation of less than 1 millimeter along the first axis 16 can be classified as mild wear; measured variation of greater than 1 millimeter along the first axis 16 but less than 2 millimeters can be classified as moderate wear; and a variation of greater than 2 millimeter along the first axis 16 can be classified as severe wear. Variations higher than a maximum threshold (e.g., greater than severe wear) can lead to the blade being rejected.

The second conveyor 62 can transfer the blade assemblies 10 to the first blade alignment assembly 40. In some aspects, the first blade alignment assembly 40 can sequentially adjust the position of the blades of each blade assembly 10 in the pallet 70.

Moving the Blade Assemblies to and From Grinders

Referring to FIGS. 9-10F, a second end of arm tool 72 can be configured to position and secure the blade assemblies 10 on the fixture 30. The second end of arm tool 72 can further be configured to move the blades about and between one or more (e.g., three) grinders 28. For example, the second end of arm tool 72 can be coupled to a robotic arm 74 that is movable along a rail 76. The rail 76 can extend between the second conveyor 62 and one or more (e.g., three) grinders 28.

At a loading/unloading station 78, the second end of arm tool 72 can be configured to pick up each blade assembly 10 and place the blade assembly 10 in a fixture 30. The fixtures 30 can be held by a fixture mount 79. In some aspects, the end of arm tool 72 can load two fixtures 30, each holding a plurality of (e.g., four) blade assemblies 10. The second end of arm tool 72 can: (a) simultaneously grip the two loaded fixtures 30, (b) move to a grinder 28 while simultaneously gripping the two loaded fixtures, (c) pick up, from the grinder 28, two additional fixtures 30′ (with ground blade assemblies 10′ thereon), (d) replace the picked up additional fixtures with the fixtures 30 holding un-ground blade assemblies, and (e) move the two additional fixtures 30′ to the unloading station 79, where the end of arm tool 72 can unload the ground blade assemblies 10′ on the pallet 70 of the second conveyor 62.

The second end of arm tool 72 can comprise a first gripper 82 that is configured to grip individual blade assemblies 10. The second end of arm tool 72 can further comprise one or more (e.g., four) grippers 84 that are configured to grip respective fixtures 30. The grippers 84 can be arranged with half of the grippers 84 (e.g., two grippers 84) on a first side 86 and half of the grippers 84 on the opposed side 87. The second end of arm tool 72 can be configured to rotate about a rotational axis 88 to selectively position the grippers 84a or the grippers 84b at the loading mounts 89 of the grinders 28. In this way, as further disclosed herein, the second end of arm tool 72 can rotate to swap, in a grinder, a fixture 30 holding ground blade assemblies 10′ with a fixture 30 holding unground blade assemblies 10.

FIGS. 10A-10E illustrate use of the second end of arm tool 72 for loading the blade assemblies 10 in the fixture, moving the figures for grinding, and returning the blade assemblies to the second conveyor 72. Referring to FIG. 10A, the second end of arm tool 72 can load blade assemblies 10 from the pallet 70 of the conveyor 62 in the fixtures 30 with the first gripper 82. The fixtures 30 can be held in loading mounts 89. Referring to FIG. 10B, the second end of arm tool 72 can grip the fixtures 30 with the grippers 84 to remove the fixtures from the loading mounts 89. Referring to FIG. 10C, the second end of arm tool 72 can move along the rail 76 to a grinder 80. Referring to FIG. 10D, the grippers 84 of the second end of arm tool 72 can grip the fixtures 30′ and remove the fixtures 30′ from fixture mounts 90. Referring to FIG. 10E, the second end of arm tool can rotate about the rotational axis 88 and place the fixtures 30 (with un-ground blade assemblies 10) in the fixture mounts 90. The second end of arm tool 72 can then return to the loading mounts 89. The second end of arm tool can then use the first gripper 82 to load the ground blade assemblies 10′ in the pallet 70 of the second conveyor 62 for further processing.

Referring to FIG. 10A, in exemplary aspects, the second end of arm tool 72 can be configured to replace a first fixture 30a with a second fixture 30b from a fixture storage bank 31. It is contemplated that the fixtures can be configured for a particular type of blade assembly 10. Thus, the system 100 can be adapted for use with multiple different kinds of blade assemblies 10.

Grinding the Blade Assemblies

Referring to FIGS. 2, 3A, and 3B, with the blade assemblies 10 held within the fixture 30 in the grinder 28, the grinding wheel 29 can be configured to pass across the blades 14 along a grinding wheel movement axis 92. In some aspects, the grinding wheel movement axis 92 can be parallel to the third axis 20 or within 30 degrees, within 20 degrees, or within 10 degrees of parallel to the third axis 20. This can contrast with conventional grinding, in which the grinding wheel moves along the thickness of the blade (with the blade removed from the blade block).

As shown in FIG. 3A, which is a schematic diagram of a blade assembly 10 and grinding wheel 29 looking along the grinding wheel movement axis, the blades 14 can be held by the fixture 30 (FIG. 2) so that the lower edge of the grinding wheel, moved along the grinding wheel movement axis 92 (into the page in FIG. 3A and shown in FIG. 3B), form a plane 94. The plane 94 can be offset from perpendicular to the first axis 16 by an angle θ1. Thus, the grinding wheel can leave a blade edge having a blade angle equal to the angle θ1. Because the blades are staggered relative to each other, the first longitudinal ends 24 of the blades can simultaneously positioned along a plane, wherein said plane forms the desired blade angle relative to the first axis 16, and the grinder can pass along said plane, thereby forming the blade angle on each of the blades. Thus, the staggering of the blades relative to each other can enable all of the blades to be sharpened simultaneously.

As shown in FIG. 3B, which is a schematic diagram of a blade assembly 10 and grinding wheel 29 looking perpendicular to the grinding wheel movement axis 92, the blade assembly 10 can be held by the fixture with the first axis 16 at an angle offset from perpendicular to the grinding wheel movement axis 92 by an angle θ2. In this way, the grinding wheel can form a relief angle on the blades 14 equal to the angle θ2.

Post-Grinding Processing of Blade Assemblies

Once returned from the grinder 28 to the pallet 70, the (sharpened) ground blade assemblies 10′ can receive one or more post-grinding processing procedures, as described further herein. It is contemplated that one or more of the post-grinding processing procedures can be omitted, other post-grinding processing procedures can be added, and the order of the post-grinding processing procedures can be rearranged as is desirable.

Referring to FIGS. 5-6, in some aspects, the ground blade assemblies 10′ can be chamfered. For example, a chamfering station 110 can comprise a chamfer grinder. The chamfer grinder can be configured to form a chamfer 25 on the each blade 14 of each blade assembly 10 in the pallet 70. The chamfer 25 can be formed at the portion of the blade furthest from the blade block (e.g., the tallest portion of the blade along the relief angle). The chamfer grinder can be, for example, a grinding wheel that is configured to pass across the blades to form said chamfer.

The ground blade assemblies 10′ can be deburred at a deburring station 120 (see also FIG. 13E). For example, the deburring station 120 can comprise a wire brush that is configured to pass across the blade edge 22 of each blade 14 of each blade assembly 10 in the pallet 70. In further aspects, a nylon brush with abrasives embedded therein or a device that blasts abrasive media across the ground blade assemblies 10′ can be used to deburr the blade assemblies.

The ground blade assemblies 10′ can be adjusted to reposition the blades relative to the blade block along the first axis 16. The blades can be positioned relative to the blade block in use positions, as shown in FIG. 5. In some aspects, the blades can be repositioned by a second blade alignment assembly 130 that is configured similarly to that of the first blade alignment assembly.

In exemplary aspects and with reference to FIG. 11, the second blade alignment assembly 130 can comprise a first linear actuator 132 that is coupled to a first guide 134. In some optional aspects, the second blade alignment assembly 130 can further comprise a second linear actuator 136 that is coupled to a second guide 138. The first actuator 132 can be configured to move the first guide 134 in a first direction to shift the blade edges 22 of the tufting blades 14 outwardly from the blade block 12 along the first axis 16. The second actuator 136 can then move the second guide 138 against the tufting blades 14 to position the tufting blades 14 in their proper grinding configuration, with each tufting blade positioned at its respective position extending the predetermined distance from the blade block 12 along the first axis. The second guide 138 can define a surface 140 (e.g., a planar profile) that defines the spaced relationship between the blade block 12 and each of the tufting blades along the first axis 16 (e.g., the incremental distances between the tufting blades).

A driver 142 (e.g., a torque screwdriver) can loosen the fastener(s) prior to engagement of the second blade alignment assembly 130 to enable movement of the tufting blades 14 relative to the blade block 12. The driver 142 can then tighten the fastener(s) after the second blade alignment assembly 130 positions the tufting blades 14 for grinding. The driver 142 can torque the fasteners to a predetermined torque.

Referring to FIG. 13B, in some aspects, the ground blade assemblies 10′ can receive or otherwise be associated with printed information relevant to the blade assembly (e.g., an identifying tag). Such printed information can include a time and date of grinding, a batch number, grinder number or other grinder identifier associated with a particular grinder that performs the grinder, or an associated plant. For example, in some aspects, each blade assembly can receive, printed thereon, a time, a date, a plant, and a batch number. A marking station 170 can be configured to print the printed information. The marking station 170 can comprise, for example, a printer, such as an inkjet printer 172. In further aspects, the marking station 170 can comprise previously printed information stored on labels that can be adhered to the blade assembly 10′.

Before marking, previous markings can be removed by, for example, a wire brush 162 at a cleaning station 160 (see also FIG. 13D). In exemplary aspects, the first end of arm tool 64 can position the blade assembly at the wire brush 162 for removing previously printed information. The first end of arm tool 64 can then hold the blade assembly 10′ at the inkjet printer 172 for printing of the printed information. In further aspects, the printed information can be applied to the blade assembly 10′ via an adhesive label. In yet further aspects, a laser can etch identifying information (a time, a date, a plant, and/ or a batch number) in to the blade assembly.

The visual inspection assembly 66 (or another visual inspection assembly) can then be used to inspect the ground blade assembly 10′. The visual inspection assembly 66 can be configured (in conjunction with the processor 1003) to inspect the printed data. In further aspects, the visual inspection assembly 66 can be configured to determine if the blade assembly 10 passes or fails at least one visual inspection metric. For example, the visual inspection metrics can comprise one or more of: whether all of the blades are present, whether the blades are properly positioned relative to the blade block, whether the blades are bent, or whether the blades have any irregular edges. If the blade assembly 10 fails, the blade assembly can be deposited in the rejection station.

In an exemplary workflow of the first end of arm tool 64, the first end of arm tool 64 can pick up an unground blade assembly 10, present the unground blade assembly at the first inspection assembly, (if not rejected) place the unground blade assembly on the pallet 70 of the second conveyor 62, and then pick up a ground blade assembly 10′, move the ground blade assembly to the wire brush 162, move the ground blade assembly to the marking station 170, move the ground blade assembly to the visual inspection assembly 66, and then place the ground blade assembly in a tray on a third conveyor 63. The third conveyor 63 can be configured to receive and transport ground blade assemblies 10′ within trays. In other aspects, and with reference to FIG. 13F, a third robotic arm 190 comprising an end of arm tool can handle the ground blade assemblies 10′. For example, in some aspects, the third robotic arm 190 can pick up a ground blade assembly 10′. In some aspects, the third robotic arm 19 can move the ground blade assembly to the cleaning station 160 (e.g., for cleaning via the wire brush 162 (FIG. 13D). In some aspects, the third robotic arm 19 can move the ground blade assembly to the marking station 170. In some aspects, the third robotic arm 19 can move the ground blade assembly to the visual inspection assembly 66. In some aspects, the end of arm tool 62 or the third robotic arm 190 can present the ground blade assembly 10′ in one or more positions at the visual inspection assembly 66 for visual inspection.

Referring to FIG. 6, in exemplary aspects, the system 100 can comprise an infeed station A, a loading station B, a visual inspection station C, an initial driver station D, an initial positioning station E, a fixture loading/unloading station F, a fixture storage station G, a chamfering station H, a deburring station I, a final driver station J, a final repositioning station K, a cleaning station L, an printing station M, a disposition area N, a tray filling station O for receiving ground blade assemblies, a tray collection station P, a makeup area Q, and an offloading station R. The infeed station can comprise or be defined by the first conveyor 60. The loading station B can be defined in part by the second conveyor 62 where the first end of arm tool 64 positions blade assemblies. The visual inspection station C can comprise or be defined by the visual inspection assembly 66. The initial driver station D can comprise the first driver 52. The initial positioning station E can comprise the first blade alignment assembly 40. The figure storage station G can comprise the fixture storage bank 31 and can hold different fixtures (e.g., fixtures 30a,b) for interchanging based on which blade assemblies are being ground. The chamfering station H can be embodied by the chamfering station 110 as disclosed herein. The deburring station I can be embodied by the deburring station 120 as disclosed herein. The final driver station J can comprise the second driver 142. The final repositioning station K can comprise the second blade alignment assembly 130. The cleaning station L can be embodied by the cleaning station 160. The printing station M can be embodied by the printing station 170. The disposition area N can define the rejection station as disclosed herein. The tray filling station O for receiving ground blade assemblies can comprise the third conveyor 63. The tray collection station P can receive empty trays 54. The makeup area Q can hold replacement blade assemblies for to replace blade assemblies that the visual inspection assembly 66 determines to be rejected. The offloading station R can comprise the third conveyor 63.

In exemplary aspects, the blade assemblies can be received at the infeed station A. The first conveyor 60 can receive the blade assemblies within a tray 54. The first end of arm tool 64 can present each blade assembly at the vision inspection station C. If the blade assembly passes, the first end of arm tool 64 can transfer the blade assembly to the loading station B. If the blade assembly is rejected, the first end of arm tool 64 can place the rejected blade assembly in the disposition area N and draw a replacement blade assembly from the makeup area Q, placing the replacement blade assembly at the loading station B. The second conveyor 62 can move each of the blade assemblies in a pallet 70 to the initial driver station D in position with the first driver 52 for loosening. The second conveyor 62 can then move each of the blade assemblies in the pallet to the initial reposition station E, aligning each of the blade assemblies with the first blade alignment assembly 40 for loosening the fasteners 26 to free the blades. The second conveyor 62 can then move back to the initial driver station D for tightening of the blade assemblies for tightening the fasteners 26 for fixing the blades.

The second conveyor 62 can then move the blade assemblies to the fixture loading/unloading station F, where the second end of arm tool 72 can place the blade assemblies in a fixture, after selecting the proper fixture from the fixture storage station G. After grinding, second end of arm tool 72 can return the blade assemblies to the second conveyor 62. The second conveyor can move the blade assemblies to the chamfer station H and then to the deburring station I. The second conveyor 62 can then move the blade assemblies between the final driver station J and final repositioning station K in order to loosen the fasteners to free the blades, align the blades, and then tighten the fasteners to fix the blades, as further described herein. The second conveyor can then move the blade assemblies for accessing of the first end of arm tool 64. The first end of arm tool can present the blade assemblies to the cleaning station L, printing station M, visual inspection station C, and then place the blade assemblies in the tray filling station O. The third conveyor 63 can then move a tray filled with blade assemblies to the offloading station R.

Computing Device

Except as where otherwise indicated, it is contemplated that any of the method steps described herein can be performed using one or more processors of one or more computing devices. FIG. 15 shows a control system 1000 including an exemplary configuration of a computing device 1001 for use with the system 100. In some aspects, the computing device 1001 can be a single computing device that controls all aspects of the system 100. In other aspects, the computing device 1001 can be embodied by a plurality of computing devices that are in communication with each other on a network. For example, the computing device 1001 can comprise, or be embodied as, a tablet, smartphone, laptop, or desktop computer. In further aspects, the computing device can be embodied as a programmable logic controller (PLC). In yet further aspects, various components (e.g., the first, second, and third conveyors, first and second end of arm tools, alignment assemblies, visual inspection assembly, drivers, printers, etc. can comprise respective controllers or computing devices that communicate with the computing device 1001/PLC to perform various functions associated with the computing device 1001.

The computing device 1001 may comprise one or more processors 1003, a system memory 1012, and a bus 1013 that couples various components of the computing device 1001 including the one or more processors 1003 to the system memory 1012. In the case of multiple processors 1003, the computing device 1001 may utilize parallel computing.

The bus 1013 may comprise one or more of several possible types of bus structures, such as a memory bus, memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures.

The computing device 1001 may operate on and/or comprise a variety of computer readable media (e.g., non-transitory). Computer readable media may be any available media that is accessible by the computing device 1001 and comprises, non-transitory, volatile and/or non-volatile media, removable and non-removable media. The system memory 1012 has computer readable media in the form of volatile memory, such as random access memory (RAM), and/or non-volatile memory, such as read only memory (ROM). The system memory 1012 may store data such as position data 1007 and/or program modules such as operating system 1005 and movement control software 1006 that are accessible to and/or are operated on by the one or more processors 1003.

The computing device 1001 may also comprise other removable/non-removable, volatile/non-volatile computer storage media. The mass storage device 1004 may provide non-volatile storage of computer code, computer readable instructions, data structures, program modules, and other data for the computing device 1001. The mass storage device 1004 may be a hard disk, a removable magnetic disk, a removable optical disk, magnetic cassettes or other magnetic storage devices, flash memory cards, CD-ROM, digital versatile disks (DVD) or other optical storage, random access memories (RAM), read only memories (ROM), electrically erasable programmable read-only memory (EEPROM), and the like.

Any number of program modules may be stored on the mass storage device 1004. An operating system 1005 and movement control software 1006 may be stored on the mass storage device 1004. One or more of the operating system 1005 and movement control software 1006 (or some combination thereof) may comprise program modules and the movement control software 1006. The position data 1007 may also be stored on the mass storage device 1004. The position data 1007 may be stored in any of one or more databases known in the art. The databases may be centralized or distributed across multiple locations within the network 1015.

A user may enter commands and information into the computing device 1001 using an input device (not shown). Such input devices comprise, but are not limited to, a joystick, a touchscreen display, a keyboard, a pointing device (e.g., a computer mouse, remote control), a microphone, a scanner, tactile input devices such as gloves, and other body coverings, motion sensor, speech recognition, and the like. These and other input devices may be connected to the one or more processors 1003 using a human machine interface 1002 that is coupled to the bus 1013, but may be connected by other interface and bus structures, such as a parallel port, game port, an IEEE 1394 Port (also known as a Firewire port), a serial port, network adapter 1008, and/or a universal serial bus (USB).

A display device 1011 may also be connected to the bus 1013 using an interface, such as a display adapter 1009. It is contemplated that the computing device 1001 may have more than one display adapter 1009 and the computing device 1001 may have more than one display device 1011. A display device 1011 may be a monitor, an LCD (Liquid Crystal Display), light emitting diode (LED) display, television, smart lens, smart glass, and/ or a projector. In addition to the display device 1011, other output peripheral devices may comprise components such as speakers (not shown) and a printer (not shown) which may be connected to the computing device 1001 using Input/Output Interface 1010. Any step and/or result of the methods may be output (or caused to be output) in any form to an output device. Such output may be any form of visual representation, including, but not limited to, textual, graphical, animation, audio, tactile, and the like. The display 1011 and computing device 1001 may be part of one device, or separate devices. The display 1011 can show one or more outputs indicative of system progress, for example.

The computing device 1001 may operate in a networked environment using logical connections to one or more remote computing devices 1014a,b,c. A remote computing device 1014a,b,c may be a personal computer, computing station (e.g., workstation), portable computer (e.g., laptop, mobile phone, tablet device), smart device (e.g., smartphone, smart watch, activity tracker, smart apparel, smart accessory), security and/or monitoring device, a server, a router, a network computer, a peer device, edge device or other common network node, and so on. Logical connections between the computing device 1001 and a remote computing device 1014a,b,c may be made using a network 1015, such as a local area network (LAN) and/or a general wide area network (WAN), or a Cloud-based network. Such network connections may be through a network adapter 1008. A network adapter 1008 may be implemented in both wired and wireless environments. Such networking environments are conventional and commonplace in dwellings, offices, enterprise-wide computer networks, intranets, and the Internet. It is contemplated that the remote computing devices 1014a,b,c can optionally have some or all of the components disclosed as being part of computing device 1001. In various further aspects, it is contemplated that some or all aspects of data processing described herein can be performed via cloud computing on one or more servers or other remote computing devices. Accordingly, at least a portion of the control system 1000 can be configured with internet connectivity.

FIG. 14 schematically illustrates the control system 1000. For example, the computing device 1001 (PLC) can be in communication with the plant network and can be in communication with: valve banks 202, operator interfaces 1060, first end of arm tool 64, the visual inspection system 66, the drivers 52, 152, the printer 172, a motion controller 1062 for controlling the second conveyor 62, and handheld human machine interfaces 1064. In exemplary aspects, the valve banks 202 can selectively provide pressurized air to pneumatic devices and/or hydraulics fluid to hydraulic devices. The operator interface 1060 and the handheld human machine interfaces 1064 can enable operators to control aspects of the system 100. For example, the operator interface 1060 and the handheld human machine interfaces 1064 can enable an operator to start or stop operation, select types of blade assemblies for processing, change speeds, pause certain routines, etc.

Exemplary Aspects

In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

Aspect 1: A method comprising:

grinding a plurality of tufting blades of a blade assembly, wherein the plurality of tufting blades are received within a blade block during said grinding,
wherein the blade assembly has a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes, wherein each tufting blade of the plurality of tufting blades has a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis,
wherein the plurality of tufting blades are spaced from each other along the third axis, and
wherein the blade assembly comprises at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block.

Aspect 2: The method of aspect 1, further comprising:

with the at least one fastener in a disengaged condition that permits movement of the plurality of tufting blades relative to the blade block, positioning, using a first guide, each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a grinding configuration; and
securing, using the at least one fastener, the plurality of tufting blades relative to the blade block in the grinding configuration.

Aspect 3: The method of aspect 2, further comprising disengaging the at least one fastener of the blade assembly prior to positioning each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in the grinding configuration.

Aspect 4: The method of aspect 3, wherein the at least one fastener comprises at least one screw, wherein disengaging the at least one fastener comprises loosening the at least one screw, wherein securing, using the at least one fastener, the plurality of tufting blades in the grinding configuration comprises tightening the at least one screw.

Aspect 5: The method of any one of aspects 2-4, wherein the first guide comprises a planar surface.

Aspect 6: The method of any one of aspects 2-5, wherein positioning, using the first guide, each tufting blade of the plurality of tufting blades relative to the blade block along the first axis comprises:

moving, by a first linear actuator, the plurality of tufting blades along the first axis in a first direction; and
moving, by the first guide and a second linear actuator that is coupled to the first guide, the plurality of tufting blades along the first axis in a second direction that is opposite the first direction.

Aspect 7: The method of any one of the preceding aspects, wherein grinding the plurality of tufting blades comprises passing a grinding wheel across the tufting blades along a grinding axis that is within 20 degrees of parallel to the second axis.

Aspect 8: The method of any one of the preceding aspects, further comprising: positioning the blade assembly within a fixture that is configured to hold the blade assembly during grinding.

Aspect 9: The method of aspect 8, wherein positioning the blade assembly within the fixture comprises positioning a plurality of blade assemblies within the fixture, wherein each blade assembly of the plurality of blade assemblies comprises a plurality of tufting blades received within a respective blade block, and wherein grinding the plurality of tufting blades comprises grinding the plurality of blade assemblies.

Aspect 10: The method of any one of the preceding aspects, further comprising:

after grinding the plurality of tufting blades of the blade assembly, with the at least one fastener in a disengaged condition that permits movement of the plurality of tufting blades relative to the blade block, positioning, using a second guide, each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a tufting configuration; and
securing, using the at least one fastener, the plurality of tufting blades relative to the blade block in the tufting configuration.

Aspect 11: The method of any one of the preceding aspects, further comprising receiving a plurality of blade assemblies positioned within a carrying tray.

Aspect 12: The method of aspect 11, wherein receiving the plurality of blade assemblies positioned within the carrying tray comprises receiving the carrying tray on a first conveyor.

Aspect 13: The method of aspect 12, further comprising moving, by the first conveyor, the carrying tray to a first end of arm tool.

Aspect 14: The method of aspect 13, further comprising: moving, by the first end of arm tool, a first blade assembly of the plurality of blade assemblies received by the carrying tray to a second conveyor.

Aspect 15: The method of aspect 14, further comprising: visually inspecting each tufting blade of the first blade assembly prior to grinding.

Aspect 16: The method of aspect 15, further comprising replacing at least one tufting blade of the blade assembly that fails inspection with a replacement tufting blade from a replacement tufting blade supply.

Aspect 17: The method of any one of aspects 8-16, further comprising: positioning, by a second end of arm tool, the blade assembly on the fixture.

Aspect 18: The method of any one of aspects 8-17, wherein the fixture is a first fixture, the method further comprising:

replacing the first fixture with a second fixture.

Aspect 19: The method of any one of the preceding aspects, further comprising deburring the plurality of tufting blades.

Aspect 20: The method of any one of the preceding aspects, further comprising cleaning the plurality of tufting blades.

Aspect 21: The method of any one of the preceding aspects, further comprising associating at least one identifying tag with the blade assembly.

Aspect 22: The method of aspect 21, wherein associating the at least one identifying tag with the blade assembly comprises printing at least one identifying tag on the blade assembly.

Aspect 23: The method of any one of the preceding aspects, further comprising: visually inspecting the blade assembly to determine whether the blade assembly passes or fails at least one visual inspection metric.

Aspect 24: The method of aspect 23, further comprising: positioning, by a first end of arm tool, the blade assembly in a rejection receptacle if the blade assembly fails said at least one visual inspection metric.

Aspect 25: The method of aspect 23, further comprising: positioning, by the first end of arm tool, the blade assembly in a passing assembly tray if the blade assembly passes said at least one visual inspection metric.

Aspect 26: A system comprising:

a blade assembly, the blade assembly comprising a plurality of tufting blades received within a blade block, wherein the blade assembly has a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes, wherein each tufting blade of the plurality of tufting blades has a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis, wherein the plurality of tufting blades are spaced from each other along the third axis, wherein the blade assembly comprises at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block;
a fixture that is configured to hold the blade assembly; and
a grinder that is configured to grind the tufting blades of the blade assembly held within the fixture.

Aspect 27: The system of aspect 26, wherein the fixture is configured to hold a plurality of blade assemblies.

Aspect 28: The system of aspect 26 or 27, further comprising:

a first blade alignment assembly that is configured to position each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a grinding configuration.

Aspect 29: The system of aspect 28, wherein the first blade alignment assembly comprises a first linear actuator that is configured to move the plurality of tufting blades along the first axis in a first direction; and a second linear actuator coupled to a first guide, wherein the second linear actuator is configure to move the plurality of tufting blades with the first guide along the first axis in a second direction that is opposite the first direction.

Aspect 30: The system of aspect 28 or aspect 29, further comprising:

a second blade alignment assembly that is configured to position each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a tufting configuration.

Aspect 31: The system of aspect 30, wherein the second blade alignment assembly comprises a first linear actuator that is configured to move the plurality of tufting blades along the first axis in the first direction; and a second linear actuator coupled to a second guide, wherein the second linear actuator is configure to move the plurality of tufting blades with the first guide along the first axis in the second direction.

Aspect 32: The system of any one of aspects 26-31, further comprising:

a first conveyor that is configured to receive a plurality of blade assemblies in a carrying tray; and
a first end of arm tool that is configured to transfer each blade assembly of the plurality of blade assemblies from the carrying tray to a second conveyor.

Aspect 33: The system of aspect 32, further comprising the carrying tray, wherein the carrying tray comprises an identifier associated with at least one parameter of the plurality of blade assemblies therein.

Aspect 34: The system of any one of aspects 26-33, further comprising a visual inspection assembly that is configured to inspect each tufting blade of the blade assembly.

Aspect 35: The system of any one of aspects 26-34, further comprising a second end of arm tool that is configured to:

transfer the blade assembly from the second conveyor to the fixture for grinding; and
transfer the blade assembly from the fixture to the second conveyor after grinding.

Aspect 36: The system of any one of aspects 26-35, further comprising a deburring station.

Aspect 37: The system of any one of aspects 26-36, further comprising a cleaning station.

Aspect 38: The system of any one of aspects 26-37, further comprising a tagging device that is configured to associate at least one identifying tag with the blade assembly

Aspect 39: The system of aspect 38, wherein the tagging device is a printer that is configured to print the at least one identifying tag on the blade assembly.

Aspect 40: The system of any one of aspects 34-38, wherein the visual inspection assembly is configured to determine whether the blade assembly passes or fails at least one visual inspection metric.

Although several embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other embodiments of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific embodiments disclosed herein, and that many modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims which follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims which follow.

BLADE GRINDING SYSTEMS AND METHODS

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CROSS-REFERENCE TO RELATED PATENT APPLICATION

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