Patent Application
20210308893
The present invention refers to a pantograph machine equipped with blades and hot-cutting pre-shaped punches and cutters, for machining panels, in particular ICF panels, with foamed or extruded materials in general (hereinafter for brevity called “machine”).
Conventional pantographs are known in the art for continuous cutting of slabs (to flat surfaces, but not perfectly coplanar in the thickness) made of expanded polystyrene, such as the cutting line numerical control Model ECO IV 4000 M2000 of DDL Ltd Such slabs, however, does not have a specific application for industrialized building, since, as currently designed hot wires of such pantographs, the slabs resulting from the cut are not suitable application in construction not suitable application in building energy-saving, environmentally friendly, as for example to build long-lasting elements perfectly modular and/or calibrated with corrugated surfaces at the same time, micro-ribbed with longitudinal grooves and undercuts lattice, with dovetails negative and positive in their facades unlimited conformation, even the most disparate.
Historically and currently, however, in the building industry, worldwide, all panels ICF origin of American and California’ are always printed on smooth facades, limited to pieces of medium size and no more than 30/40 centimeter high, by specific aluminum molds suitably molded and shaped for the purpose, and for this, if not last, reason serve multiple molds of aluminum to produce obviously only one type of panel ICF outlined in its shapes and sizes such as length and thickness height, certainly not in said mold is made of aluminum can produce simultaneously a plurality of thicknesses and/or forms of panels ICF, above all the same,’ co-molded with plastic inserts PP. In fact, we face high investment only for their specific design and purchase them, thereby implying equally high costs due to the large steam needed for the sintering of virgin EPS beads/PSE, and with obvious disadvantage of the remarkable timing of molding, for the production of such, panels ICF, through appropriate printers and modified for the purpose, which are also very costly in purchase and management, not ‘easily available in the industries and in the world market.
The present invention relates to the rapid manufacturing of elements of any geometry with even the most complex shapes and without bond materials, and in particular the realization of EPS foam panels and/or extruded of any shape, size and in length, height and thickness, or having multiple and submultiples measures, known internationally as ending scientific INSULATED CONCRETE FORM (ICF), contrary to the common conception of molding has become obsolete and static to get the same products made by the machine in question with the classic molding obsolete arid static, it would take a large number of molds, dedicated to the type of panel ICF or other items, which may not allow you to print certain ICF panels, above all, it becomes almost impossible if you do not print special pieces as decorations, string courses, capitals, borders, window and door insulation, thermal containers in general, satisfying the requirements mentioned above, and an equal number of special and special printing presses, with obvious and consequent high investment.
Moreover, the machines used for the molding of panels only present in the industries and on the world market are not always adaptable to technical molds integral carriages with sliding pistons, defined complexes, in which during the pre-molding are integrated plastic inserts from co-print during the production cycle.
This, obsolete moldi-ng system described is not only very costly both in the times at both the molding costs of said panels ICF or other thermally insulating elements.
From all this, are deduced the dynamic and exclusive elasticity of the machine in question, either as a capacity to adapt to any type of product to be produced and the type of production, both as variability of composition depending on the product to be cut and/or milling, they are hollow blocks in the most diverse shapes, ICF panels of any size in thickness, height and length, cornices in the most, disparate types and conformation, they also stringcourses in the most diverse types and shapes, decorative capitals and jambs decorative doors and windows designed to encapsulate’ frames generally high value insulation, arches and arches, and so serves no restrictions to create these elements in monolithic (inner face with hollow “T” and/or “cross” for the ‘of housing any type of connector need for the conjunction of multiple types of components, thus obtaining an obvious advantage in’ assembly of a formwork ICF, and the housing bound the longitudinal rods and the stirrups horizontal variable pitch, (according to the known reinforcement steel) of respectful all international standards in terms of energy savings, soundproof and structural.
However, as seen, the machines of an old design notes for cutting polystyrene and similar material are only a heated wire for “Joule effect” by means of electrical energy, and fail to realize, of course, a cut coplanar calibrated and perfect, especially when working elements and/or panels over the linear meter. Therefore, the complete machining, defined in a production cycle, of the very few items that you would be able to realize would lead to high costs and with obvious times that are acceptable.
The purpose of the present invention is to construct a modular machine according to requirements, able to work quickly, and polyhedral, that is constructively very simple and inexpensive it from the basic model, with a very high operating speed because of the unique and innovative technology applied based on multiple wires and shaped dies even in the most diverse conformations heated for “Joule effect” through electricity via a temperature controller and multiple cutters properly shaped for the purpose, all controlled by CNC and software specific.
The inventive machine is extremely versatile, it does combine all the best features of the machine's main feature is that it can integrate a number of different cutting technologies: oscillating blade, rotary blade and cutting line (with an additional kit), a number of advantages for easily produce any type of product in any material.
The inventive Machine and advantageously producible in a plurality of versions that differ from each other only for the trim size and type of materials to be machined.
Loading and unloading of the block preferably expanded polystyrene EPS to be cut is facilitated by the roller system and by the conveyor belts. on the working plane, that automatically rotates to make a cut in accordance with the same. shape rotated 90° in the working plane.
The automation of the inventive machine is controlled by the software of the personal computer, the same included into the control panel.
To recognize the outline of the specific drawing of the article to be cut and/or milling, it is possible to use: the table digitizer, scanner, or even a drawing made with a CAD program with application specific purpose.
The work center described below realizes, by a block (A) of parallelepiped shape preferably of polystyrene foam EPS and/or extruded or other foam materials of the dimensions from the classic standard sizes of 400×100×120 cm or of other measures arranged in—a position vertical and/or inclined (the inventive machine can be built for the processing of special products in horizontal, and the block size (A) are not binding, because the machine can adapt to the dimensions of the block (A) built by the user, given that his inventive feature is also the ‘exclusive extensibility of the frame both in height, width and in length (figure not shown) with obvious replacement of the screws (or belt) of transmission (in the extending direction), the panels ICF variable geometry (in thickness, height and length), which artifacts are essential for the assembly of a formwork-base-slab formwork and related interposed the floor of any dimension (linear, angular, shaped with one or more cavities attached in any format or size they are.)
This inventive machine is characterized for the perfect cut, advantageously coplanar, and calibrated at the same time advantageously performs the milling of the panels ICF necessary for the construction of specific elements for foundations thermo-insulating capsule integral, hollow elements in EPS with geometry variable for multiple types of elements for linear or radial assemblage of stairs without the constraints of even the most complex geometries, internal and external walls, panels or slabs for floors, roofs, pitched roofs acoustic macro-ventilated micro-ventilated roofs, decorative elements such as monolithic, insulating sleeves for columns, hollow columns in the most diverse conformations for containment armor-’ and structural concrete, monolithic string courses with pits in the most diverse conformations for containment armor and structural concrete, cornices for containment armor and structural concrete in the most diverse shapes, decorative capitals in more diverse conformations for containment armor and structural concrete, insulation jambs for doors and windows, in the most varied shapes, armor for containment and isolation of structural concrete, in the most varied shapes, thermal seismic bins in the most diverse conformations acts to contain armor and isolation of structural concrete, round-headed arches insulation in the most diverse conformations acts to contain armor and insulation of structural concrete, and anything else necessary for the construction of buildings for private, public and industrial respectful of international standards ASTM.
The execution of the elements mentioned above, even in the most complex thickness and diameter, can be advantageously for steel rule cutting hot (single and multiple) linear and also shaped in many different shapes, hot-wire (single and multiple) linear and shaped milling and grading of articles made tools properly shaped for the purpose. The machining systems cited (hot cutting and milling) can succession sequentially or simultaneously, and always according to a sequence controlled by a numerical control (CNC) slaved to the inventive machine, in which are implemented the various processing cycles programmable via software of commerce or specific specifically designed for these features. The above and other objects and exclusive advantages of the invention, as will appear from the following description, are achieved with a pantograph machine accompanied, for example, cutting blades and dies hot and cutters or other special tools forming part of said invention conformed to ‘achieve the purpose, for the manufacture of panels, in particular panels ICF, with foamed materials or ‘extruded in general, as described in claim 1. Preferred embodiments and non-trivial variations of’ the present invention are the subject of the dependent claims.
It is understood that all of the appended claims form an integral part of the present description.
The present invention will be better described by some preferred embodiments, given as an example and not limitative, with reference to the accompanying drawings, in which:
a illustrate a first variant of the Machining center of the present invention;
a show a second variant of the Machining center of the present invention;
a illustrate a fourth variant of the Machining center of the present invention;
Referring to the Figures, is illustrated and described a preferred embodiment of the pantograph machine equipped with blades by hot cutting and milling cutters, for processing of sheets, slabs, in particular panels ICF, with foamed materials or extruded in general, the present invention. Be immediately obvious that it will be possible to make what is described numerous variations and modifications (for example related to shape, design, sizes, thicknesses, heights, lengths arrangements and parts with equivalent functionality) without departing from the scope of the invention as it appears from the claims attached.
The work center described below produces quickly and easily, from a block of. parallelepiped shape, preferably of sintered polystyrene, also the size standard 400 centimeter×100×120 centimeter or other multiple measures (the size of the block or element to be work are not binding, because the machine (1) can be built in any size and/or adapted to the dimensions of the block or element found in the country in which it operates) components for the assembly of a mold (linear, angular, shaped), for the construction and assembly of all types of thermal insulation panels for on-grade foundations also complex geometry, walls thermo acoustic inner and outer panels or slabs for floors and acoustic, acoustic pitched roofs, roof ventilation thermo acoustic macro-, micro-ventilated. roofs thermo acoustic elements specific for foundations thermo-insulating capsule integral, hollow elements in EPS with variable geometry, for the multiple types of elements for the assemblages of linear scales or without radial constraints of even the most complex geometries, external and internal walls, panels or slabs for floors, sloped roofs, roofs acoustic macro-ventilated, decorative elements such as monolithic, insulating sleeves for columns, hollow columns in the most diverse conformations for containment armor and structural concrete, monolithic stringcourses cables in the most diverse conformations for containment armor and structural concrete, cornices for containment armor and structural concrete in the most diverse shapes, decorative capitals in the most diverse conformations for containment armor and structural concrete, insulation capsule jambs for doors and windows, in the most varied shapes, armor for containment and isolation of the structural concrete in. more diverse conformations, thermal seismic bins in the most diverse conformations acts to contain armor and insulation of structural concrete, round-headed arches insulation in the ‘most diverse conformations acts to contain armor and insulation of structural concrete, and whatever else is necessary for the realization models for ad hoc buildings monolithic and homogeneous hyper-insulated breathable, will be in private, public and industrial sectors.
Said manufactured articles obtained by this cutting process with the inventive machine, advantageously allow associating them and/or combining them between them being perfectly calibrated, for the creation of formwork shuttering ICF-sectional in site. Said articles and/or panels ICF thanks to the cavities obtained in the cutting process of the inventive machine, advantageously can integrate multiple types of special connectors, in containment integral, for example, of conventional steel rods, profiles of any nature.
The execution of the components, namely in particular the panels ICF described above, may take place by steel rule cutting heated (single and multiple without limitation conformation or integration of wire nickel cadmium as a basis sharp, linear and/or suitably shaped for the purpose, a heated wire (single and multiple, without limitation) linear and shaped, with one or more milling cutters and/or with electro-spindles, without limitation to obtain manufactured articles perfectly calibrated, the various systems mentioned machining (cutting through specific punches pre-shaped wire with embedded pre-shaped cutting edge as a base, and through specific milling cutters and/or electro-spindles suitable for this purpose) may succession sequentially or simultaneously, and always according to a sequence controlled by a numerical control (CNC) slaved to the machine (1) in which are implemented the various processing cycles pre-programmable and post-programmed for a simple and fast production of each type of artifact.
The descriptive part of the machine (1) inventive step that follows is broken down into components and related machining, for a better understanding of the unique versatility of the machine (1) itself.
With reference to
Such a machine (1) allows the machining of a panel linear and perfectly calibrated. The panel has linear dimensions varying from a minimum of 120×15 (H)×5.0 and/or 7.5 (D) cm to 120×60 (H)×30 (P) according to multiples and submultiples of 15 centimeter for (H) and 2.5 cm and submultiples for (P) without limitation of other measures even if not multiple to each other. This panel presents grooves dovetail undercut and/or radiuses sides 120×H, linear grooves or polygonal alternate male-female (provided that dovetails may also be parallel to each other as-follows Male-Male-Female-female, but not limited to undercut radius and shape) on the sides 120×P, linear grooves alternate male and female sides H×D.
The inventive machine (1) for processing said panels ICF in EPS expanded polystyrene foam and/or other foamed materials, gummy of any nature and density, which are also recycled, polyurethane foam and others, consists of a castle (1′) to vertical uprights having grooves/longitudinal slots, supported by a base (2) which houses a supporting surface (3) equipped with electro-pneumatic cylinders (4).
The block of expanded polystyrene foam EPS and/or other foamed materials gummy, of any density, is also recycled, polyurethane foam and others without limitation (A), by means of a known carpet and/or a roller conveyor is placed in position plane (3) centered on the castle (1′). In the upper part of this, are placed various tools (punches linear and/or shaped, wires, drills and/or electro-spindles) in the order described below starting from the plan (3):
Using a single wire (16), the cutting operation. in horizontal begins as soon as the frame-dies carriers has exceeded the safety altitude (controlled by control equipment to laser-photocells of known construction) and have been performed by the grooves cutters.
As previously mentioned, the block in EPS polystyrene foam or other foam materials or gummy of any density, albeit recycled, such as polyurethane foam and other insulating materials of any nature, rests on a board (3) equipped with electro-pneumatic cylinders (4) load-bearing rod end a sphere self-supporting. The latter, activated by CNC depending on the format of the panels to work in production,’ protrude from the table (3) and rise as the blocking in EPS polystyrene so that—the frame (5) carrying punches (6) can escape completely from said block at the end of the vertical cut.
The table (3) can be equipped with rotary motion about its axis; fact, in the execution of assailable elements to a cylinder (hollow columns for pillars in many different forms, shuttering/formwork for pillars, bins thermal), once effected cutting with the cutting dies/punches hot, you may need to make specific milling with predetermined angles to perform with electro-spindle (25).
For the maintenance of the panels ICF cut on the sides of the castle (1′) opposite the entry and exit of the block in EPS polystyrene foam, are arranged in the vertical direction of the electro-pneumatic cylinders equipped end of the stem of pointy appendages (23) or suction cups (24), which intervene constraining the element actuated by the CNC only after the passage of the frame” (5) carries cutting dies-punches (6), and are deactivated returning back at the end of all the processes.
Starting from the top, the panels which are completely machined can be evacuated from the work area through the gripping devices, described subsequently, combined with the machine (1) and operated by the same CNC.
In the upper part of the castle (1′), are placed a suction hood (22) of the fumes generated by the cutting die and wire and against a hood (22a) for maintaining the cutting temperature.
A different construction of the machine (1) is illustrated in
With reference to
The translation mechanism and tilting (29) shown schematically in
The metal arms (32) can, depending on the working cycle, release the group of panels ICF on the table (34) which can rotate by means of a geared motor (35), resume the group of panels ICF and deposit the second station.
Execution of machining operations on the sides D×H provides a support (36) port—electro spindles (37) arranged vertically with variation motorized mechanical and/or manual distance between the one and the other (known mechanism consists of the adjusting screw with bolts and locking), moved by the kinematics (38) always consists of specific rails, screw and motor (similar to devices 26-27-28). This kinematic system is illustrated on the drawing only in the direction parallel to the group of panels ICF B for simplicity, but in reality the kinematic mechanism is also present in the orthogonal direction (kinematic cross) for the evacuation from the working area when it is in action at least a milling cutter (24), for the approach to the group of panels ICF and the evacuation for the passage of the group itself machining has been completed. Being the station (2) equipped with a rotary table (39) analogous to (3) [including devices (4)], the milling operation, on one side P×H, subsequently, after having carried out the rotation of the table (39), repeats the processing on the other side P×H.
Milling operations performed by the devices 36-37 can also be obtained with the kinematic mechanisms (40) shown schematically in
In
With reference to
With reference to
On the supports (47-49-50) port electro-spindles (46), the position of the latter can be fixed or can be varied mechanically and/or manually in distance between the one and the other (known mechanism, consisting of adjusting screw and locking by means of bolts).
In
With reference to
With reference to
With reference to
With reference to
As regards the application software that manages the machine (1) inventive, is meant by this term a CAD-CAM to be installed directly on the server Machine (1) and/or in a workstation external and networked with the aforesaid server, and in any case remotely connected with the principal place of business.
The supervision software and compiler working on operating system MS-DOS (but also in a window of Windows) and you can replace the PC with any one and′ in no time or even perform the supervision software from floppy disk.
There are at least a CD-ROM with all the back-up system (source, compiler, supervisor and utility) but also an emergency floppy disk, able to reboot and supervision on any PC with a floppy disk and a RS232 serial port. You have the option to connect a second PC where immediately install all the “system.”
The 2D/3D CAD is implemented in an application specific structured as follows:
The machine (1) inventive step can advantageously be transported through a specific transport system (not shown).
On the base of the Machine (1) are arranged (by screwing or welding) devices to cylindrical or polygonal hole for insertion of gripping of an arm, which moves by means of hydraulic cylinders on a trailer. Once inserted the gripping, by means of the hydraulic cylinder, the machine (1) undergoes a rotation of 90°, so as not to exceed the maximum overall height of 4 meters. Subsequently, by means of the cylinder, the Machine is moved so as to fall in the shape of the trailer.
With reference to
Finally, with reference to
The use of at least two robots (400) suitably customized with special mandrels (500) on which are fixed to the wrist articulated suitable cutters (600) suitable for the purpose, guarantees the processing of blocks without bond, slabs, panels ICF, elements decorative cornices, string courses, roller-shutter door thermal, etc. This solution allows carrying out the milling of at least two long sides of the panel and, with simple programming, to perform additional millings in the direction or inclination completely different from each other. The operating cycle provides that the panels conveyed via a carpet and/or roller conveyor known, within the cell, they are centered with the device (200) and blocked automatically by the presser plane (300) on the support' surface (100); a simple zero authorizes the life-cycle at the same time the two robots. At the end of milling the panel or decorative element is released on a removal conveyor belt (not shown), invoking a second panel always transported by means of a carpet and/or roller conveyor, not shown. The cell is completely enclosed in a protective structure consists of transparent panels in shatterproof material, assembled on a metal frame or aluminum and interlocked doors. A suitable vacuum system provides the evacuation of the chip in a specific collection tank. All the operation of the cell is controlled by a numerical control (CNC) which is accommodated in the cupboard door electrical wiring (700); specific software allows the management of the drawings and their transformation into tool paths which will be executed by the two robots individually or simultaneously depending on the conformation and the shape, even the most disparate, the piece to be performed.
As far as the technological-productive flexibility, the advantages are so numerous that the list can only be schematic:
The advantages compared to traditional systems are considerable:
The same block (A) parallelepiped expanded polystyrene (EPS-PES) will be subjected to shear to simultaneously create multiple panels ICF in extremely short times (ratio 1 to 9 compared to the classic molding of panels ICF), depending on the requirement of a thickness and measure; in turn, along the processing chain, such panels ICF will be bound in a lane adjustable to size according to the measure of the panel ICF, so that the drills at very high speed adjustable. invention, as further application, able simultaneously milling the heads of the panels ICF creating the necessary design as teeth, recesses, tapping, and/or ribs negative and positive in order to stack them with a solid interlocking also through elongated elements, etc.
It should be pointed out that the steel rule cutting linear and/or pre-shaped, in hot wire panels ICF in EPS not only allows to have an exclusive breathability due to its rough surface thus obtained by the procedure, which is still a further and exclusive advantage as ideal support for be plastered with a traditional method, and have ensured adherence solidarity over time.
The method and the inventive pantograph described above therefore allow to considerably reducing the production costs of the panels ICF in EPS and not least the conventional ones. Still, these panels ICF can be printed without having to meet multiple constraints for their production, as for example, in the prior art called Insulated Concrete Forms, ICF, the fact of having to find big industries that have the specific machinery for their production.
Finally, with the inventive method, it is not difficult to find the raw material on site, with the obvious advantage of not having to transport large volumes over long distances in order to respect the environment, however, expensive, and yet, the inventive technology not only provides performance extremely unique and innovative, but also respects the environment with less pollution, making it cheaper in every kind of work in comparison with the conventional printed panels ICF.
An application of the inventive method is described below. For Example: 20 blocks/hour were used with density 15 g/It and dimensions 600×1,200×4,000 mm, whereby during molding were obtained about 1060 sheets, panels ICF thickness of 75 mm with facades representing the figures volutes, as continuous ribs horizontally (ribs modular necessary for the stacking of a plurality of panels) only to be cut in the top and bottom surfaces with the appropriate dovetail or other representations via the pantograph amended of the present invention.
The ratio of cut slabs of. panels ICF in comparison to the classic known molding was 1 to 9, and therefore are evident its unique effectiveness, as well as its industrialization cheap and easy, thanks to the lack of necessary equipment, except that implementation of machinery always existing.
As a comparative example, we used a classical and conventional aluminum mold with four figures (four panels ICF), having an average of 2.5/3.0 minutes for printed for simple sheets or panels ICF containing longitudinal slots at half height of the panel ICF even if the same are measures of maximum height of 30/40 Centimeter.
Obviously, taking into account the 2.5-3.0 minutes cited, they are printed with, such a conventional mold in aluminum 24 panels ICF: therefore, in order to achieve the same quantity obtained by the above-mentioned process of the invention, it would take at least 44 hours with such a conventional mold.
| Number | Date | Country | Kind |
|---|---|---|---|
| TO2011A001129 | Dec 2011 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IT2012/000371 | 12/7/2012 | WO | 00 |
