|
(11) | EP 1 493 696 A2 |
| (12) | EUROPEAN PATENT APPLICATION |
|
|
|
|
|||||||||||||||||||||||
| (54) | Machine for filing trays with mosaic terrerae or the like |
| (57) A machine (1) for filling trays (V) with mosaic tesserae (T) or the like, comprising
a first continuous conveyor (3) for conveying mosaic tesserae, a second continuous
conveyor (4) for conveying trays (V) for containing mosaic tesserae (T), and means
for transferring the tesserae from the first conveyor to the trays, which are movable
between the first and second continuous conveyors. |
[0001] The present invention relates to a machine for filling trays with mosaic tesserae or the like.
[0002] In the field of the production of paving or cladding articles, particularly made of ceramic, glassy or stone-like materials, ready-to-lay mosaic articles are known which are constituted by a mesh-like binding sheet on which the tesserae of the mosaic, usually distributed uniformly in rows and columns, are bonded.
[0003] One of the currently known methods for manufacturing these articles substantially comprises a step of preparing the individual tesserae, a step of distributing and placing the tesserae on containment trays, arid a step of bonding the binding sheet to the tesserae thus distributed.
[0004] The trays have a grid-like containment face; the mesh of the grid forms compartments, each of which is adapted to contain a tessera and is delimited by edges that form separation spaces between the various tesserae; such spaces are intended to constitute the so-called joints upon installation of the articles.
[0005] The tesserae rest their exposed surface against the containment face, so as to be able to bond the binding sheet onto their opposite laying face, which is directed outward.
[0006] The trays are currently filled with manual methods by specialized personnel, which picks up the individual tesserae, for example from bags or crates, and inserts them one by one in the individual compartments of the grid, arranging them with their laying face outward.
[0007] The assigned personnel must be precise, skilled, patient and dexterous in handling the individual tesserae, in recognizing their laying face and in placing them in the individual compartments, so as to avoid the formation of defects, such as voids or upside-down tesserae, in the produced articles.
[0009] These manual methods for filling the mosaic tessera supporting trays are not free from drawbacks, including the fact that they require the use of a large number of expensive specialized labor and long execution times, which slow the entire production process, making its management and scheduling very difficult and uncertain.
[0010] It is in fact noted that the speed of the subsequent steps of the production process, particularly bonding, depends on the execution times of tray filling.
[0011] Another drawback of known methods consists in that since they depend on the skills of the labor employed, they do not ensure constancy of production in terms of quantity and quality.
[0012] The aim of the present invention is to eliminate the drawbacks noted above of conventional methods, by providing a machine for filling trays with mosaic tesserae or the like, which allows to reduce the use of specialized labor, to contain times and costs for filling the trays, and to render the speed of the subsequent steps of the production process independent of the tray filling speed, so as to be able to streamline and optimize the scheduling and management of the process.
[0013] Within this aim, an object of the present invention is to provide a machine that allows to produce mosaic articles that are defect-free and with results that are repeatable and constant both in terms of quality and in terms of quantity.
[0014] Another object of the present invention is to provide a machine that is simple, relatively easy to provide in practice, safe in use, effective in operation, and has a relatively low cost.
[0015] This aim and these and other objects that will become better apparent hereinafter are achieved by the present machine for filling trays with mosaic tesserae or the like, characterized in that it comprises a first continuous conveyor for conveying mosaic tesserae, a second continuous conveyor for conveying trays for containing mosaic tesserae, and means for transferring said tesserae from said first conveyor to said trays, which are movable between said first and second continuous conveyors.
[0016] Further characteristics and advantages of the present invention will become better apparent from the detailed description of a preferred but not exclusive embodiment of a machine for filling trays with mosaic tesserae or the like, illustrated by way of non-limitative example in the accompanying drawings, wherein:
Figure 1 is a schematic front view, shown partially in phantom lines, of the machine according to the invention;
Figure 2 is a schematic top plan view of the machine of Figure 1;
Figure 3 is a schematic enlarged-scale view of a first portion of the first conveyor of the machine of Figure 1;
Figure 4 is a top plan view of the machine of Figure 3;
Figure 5 is a schematic side view of a detail of Figure 3;
Figure 6 is a schematic enlarged-scale view of a second portion of the first conveyor of the machine of Figure 1;
Figure 7 is a schematic sectional view, taken along the line VII-VII of Figure 6;
Figure 8 is a schematic top plan view of Figure 6;
Figure 9 is an enlarged-scale schematic top plan view of a third portion of the first conveyor of the machine of Figure 1;
Figure 10 is a schematic enlarged-scale view of a portion of the second conveyor of the machine of Figure 1;
Figure 11 is a schematic top plan view of Figure 10;
Figure 12 is a schematic enlarged-scale view of the transfer means of the machine of Figure 1;
Figure 13 is a schematic top plan view of Figure 12;
Figure 14 is a schematic side view of the transfer means of the machine according to the invention.
[0017] With particular reference to the figures, the reference numeral 1 generally designates a machine for filling trays V with mosaic tesserae T or the like, particularly made of ceramic, stone-like, glassy material or the like.
[0018] The machine 1 comprises a frame 2 for supporting a first continuous conveyor 3 of tesserae T, a second continuous conveyor 4 of trays V, and means 5 for transferring the tesserae from the first conveyor 3 to the trays V, which can move between the first conveyor 3 and the second conveyor 4.
[0019] The machine 1 is of the automated type, since it is functionally controlled by a programmable control and management unit, which is not shown since it is of the conventionally known type.
[0020] The first conveyor 3 comprises a receiving segment 6, which is fed with the tesserae T and proximate to which there are means 7 for orientating the tesserae T which are suitable to arrange them so that their exposed face is directed toward the first conveyor 3; a segment 8 for singling the tesserae T, which is suitable to guide them individually in a row; and a segment 9 for sorting the tesserae T that is suitable to sort them so that they are mutually spaced with a constant pitch in at least one row for feeding the transfer means 5.
[0021] The singling segment 8 is interposed between the receiving segment 6 and the sorting segment 9.
[0022] The second conveyor 4 comprises an input segment 10 that is fed with the empty trays V and is arranged upstream of a segment 11 for the timed advancement of the trays V, proximate to which the transfer means 5 for filling the trays V can move, the advancement pitch of the trays V being functionally coordinated with the speed of the transfer means 5.
[0023] Between the input segment 10 and the time-controlled advancement segment 11 there are interposed means 12 for adjusting the feeding of the empty trays V.
[0024] The second conveyor 4 further comprises an output segment 13, which is arranged downstream of the timed advancement segment 11 in order to remove the trays V' filled with the tesserae T.
[0025] Upstream of the receiving segment 6 (Figures 3-5) there are means for feeding the tesserae T, which are not shown since they are of a conventionally known type and are constituted for example by a bowl that is provided internally with a spiral channel for the advancement of the tesserae and is associated with vibrating means suitable to facilitate the sliding of the tesserae along the channel; the discharge end of the channel is arranged proximate to the receiving segment 6, and the tesserae T that exit from it are fed substantially upright, vertical or inclined, i.e., with one side directed toward the receiving segment 6.
[0026] The receiving segment 6 is constituted 'by a conveyor belt 14, which is closed in a loop around drums 15; one of the drums is a driving drum 15a associated with a first motor 16 and the other drums are driven.
[0027] The orientation means 7 comprise sensing means, such as for example an optical sensor 17 or the like, suitable to recognize the exposed face or the laying face of the tesserae T or both and functionally coordinated with means for overturning the tesserae T, such as for example a blower duct 18, which is associated with air supply means and is arranged with its outlet substantially transversely to the tesserae T.
[0028] The orientation means 7 further comprise a surface S for the abutment of the tesserae T, which lies substantially longitudinally above an input section of the receiving segment 6 and proximate to which the optical sensor 17 and the blower duct 18 are arranged.
[0029] The abutment surface S can move concordantly with the receiving segment 6 and is constituted for example by the active portion 19a of a belt 19, ribbon or the like, which is closed in a loop and winds around pulleys 20, wheels or the like which are motorized by a second motor 21.
[0030] The tesserae T (Figures 4 and 5) are fed so that one side is directed toward the belt 14 (receiving segment 6), so that one of their faces is directed toward the optical sensor 17, ad are conveyed so that either their exposed side or their laying side is substantially in contact with the abutment surface S.
[0031] The optical sensor 17 recognizes the face of the tesserae T that is directed toward it, so that the tesserae T that rest their exposed surface against the abutment surface S are overturned by gravity so that their exposed face rests on the belt 14 proximate to the end edge of the belt 19, i.e., when contact with the abutment surface S ceases, while the tesserae T that rest their laying face against the abutment surface S are overturned so that their exposed surface rests on the belt 14 by the jet generated by the blower duct 18.
[0032] The singling segment 8 (Figures 3 to 8) comprises two contoured side walls 22, which are arranged, at a mutual distance that can be adjusted by way of registration elements 23, along the two opposite sides of the first conveyor 3 and form a profile 24 for guiding the tesserae T that is suitable to convey them individually in a row along an advancement channel 25 that is substantially as wide as said tesserae.
[0034] The input portion 8a is substantially co-planar to the receiving segment 6, and at said portion the side walls 22 are arranged above the belt 14 that conveys the tesserae T along the guiding profile 24 and the initial segment of the channel 25.
[0035] The output portion 8b is constituted by a chute 26, which is provided with means 27 for adjusting its inclination, such as slots and screws, with respect to the input portion 8a and to the sorting segment 9; advantageously, the receiving segment 6 is in fact arranged at a higher level, with respect to the horizontal plane, than the sorting segment 9, so that the tesserae T slide by gravity along the chute 26.
[0036] Presser means 28 are provided above the chute 26 and are suitable to prevent the overturning of the tesserae T that slide along it.
[0037] The sorting segment 9 comprises a first chain 29, a belt, a ribbon or the like, which is closed in a loop around sprockets 30, pulleys, drums or the like, one of which is for example a driving sprocket 30a associated with a third motor 31 while the other sprockets are driven.
[0038] The first chain 29 is divided into a plurality of transverse links 32, in each of which there is a seat 33 for containing a single tessera T.
[0039] The seats 33 are mutually spaced with a constant pitch of presettable and adjustable value so that the tesserae T are sorted equidistantly; the distance between two adjacent tesserae can be usually greater than, or equal to, the separation distance with which they must be inserted in the trays V and substantially corresponds to the joints of the mosaic articles that can be obtained.
[0040] In the embodiment shown in Figure 9, the pitch between the seats 33 is adjustable by means of slots 34 and screws 35, by way of which the links 32 can be fixed to the first chain 29; however, alternative embodiments, such as for example shoulders for the rear abutment of the tesserae and lateral brush-like guides, are not ruled out.
[0041] The timed advancement segment 11 (Figures 10 and 11) comprises a pair of bars 36, which are mutually parallel and spaced and on which the sides of the trays V rest, and a second chain 37, a belt, a ribbon or the like, which is closed in a loop and is wound about respective sprockets 28, pulleys, drums or the like, one of which is for example a driving sprocket 38a associated with a fourth electric motor 39 of the step type, the other sprockets or the like being driven elements.
[0042] The second chain 37 is arranged between the bars 36 and below the resting surface formed by it, and is further provided with pushers 40, which are suitable to make contact with the rear edge of the trays V in order to push them so that they advance stepwise along the bars 36.
[0043] The input segment 10 comprises a plurality of rollers 41 for supporting the trays V; said rollers are supported so that they can rotate freely by the frame 2 and are arranged mutually side by side so that their longitudinal axes are substantially at right angles to the conveyance direction of the trays V.
[0044] The rollers 41 are rendered rotatable by way of means 42 for transmitting the rotary motion by traction, which are associated with motor means 43 with the interposition of engagement and disengagement means of the clutch type.
[0045] The transmission means 42 are constituted by a driving belt 44, which is closed in a loop and is wound around respective pulleys 45, of which one is a driving pulley 45a that is associated with the motor means 43, which are constituted by a fifth motor 46 with the interposition of a clutch; the active portion 44a of the driving belt is in contact with the lateral surface of the rollers 41.
[0046] The timed advancement segment 11 comprises an input end 11a, while the input segment 10 comprises an exit end 10a, which are partially inserted in each other and proximate to which the means 12 for adjusting the feeding of the trays V are arranged.
[0047] The means 12 for adjusting the feeding of the empty trays V to the timed advancement segment 11 comprise a front retainer 47 for the tray V" to be filled and a rear separator 48 for separating the tray V" to be filled from the empty trays V that follow it.
[0048] The retainer 47 and the separator 48 are associated with respective hydraulic or pneumatic linear actuators 49 and 50 that are suitable to actuate them with an alternating and discordant motion between respective active and inactive configurations.
[0049] In the particular embodiment shown, the retainer 47, such as a pad, and the separator 48, such as a rod, are arranged under the advancement plane formed by the rollers 41 and are rendered movable alternately between an active configuration, in which they are raised so as to affect the trays V, and an inactive configuration, in which they are lowered and do not interfere with the trays V.
[0050] There are also sensors for detecting the position of the trays V, which are functionally coordinated with the adjustment means 12 and are not shown.
[0051] When the input segment 10 (rollers 41) is in motion, the retainer 47 is in the active configuration, in order to engage the front edge of the incoming tray V" to be filled, and the separator 48 is in the inactive configuration.
[0052] When the retainer 47 affects the tray V" to be filled, the input segment 10 (rollers 41) stops and the separator 48 is moved into the active configuration in order to engage the front edge of the tray V that follows the tray V" to be filled, separating it therefrom, while the retainer 47 is moved into the inactive configuration in order to allow the free advancement of the tray V" to be filled.
[0053] The tray V" to be filled is pushed by the pushers 40 of the second chain 39 toward the timed advancement segment 11, at which it is filled with the tesserae T.
[0054] The transfer means 5 (Figures 12-14) comprise an automated handling unit 51, which is provided with means for gripping the tesserae T, which are constituted by a suction unit 52 suitable to pick them from the first conveyor 3 and release them onto the tray V" to be filled which rests on the timed advancement segment 11.
[0055] The suction unit comprises at least one arm 53 that is supported so as to rotate about a substantially vertical axis A and is associated with a sixth motor 54.
[0056] The arm 53 is provided in a lower region with at least one row of suction cups 55, which are associated by means of a duct 56 with a suction circuit and are mutually spaced with a constant pitch whose value can be predefined.
[0057] Advantageously, the suction unit 52 comprises elements for adjusting the pitch of the suction cups 55, which are not shown.
[0058] As is known, the trays V are substantially constituted by a supporting plate, which is divided in an upper region into a plurality of compartments N for containing the tesserae T which are distributed in rows and columns.
[0059] Conveniently, the first conveyor 3 and the second conveyor 4 are mutually parallel and are actuated in discordant directions, indicated schematically by the arrows F3 and F4.
[0060] The arm 53 is movable alternately between a picking configuration, in which it is aligned with the sorting segment 9 of the first conveyor 3, from which it removes a row of tesserae T, and a release configuration (indicated by the dashed line L), in which it is perpendicular to the timed advancement segment 11, i.e., parallel to a row of compartments N of the tray V" to be filled, in order to release the tesserae T into the row of compartments N that lies thereat.
[0061] When the arm 53 is in the release configuration, the tray V" to be filled is motionless; when the arm 53 reaches the picking configuration, the tray V" is made to advance with a step that substantially corresponds to the width of the compartments N.
[0062] Conveniently, the pitch of the tesserae T aligned along the sorting segment 9 and the pitch of the suction cups 55 is substantially equal to the separation distance between two contiguous compartments N of the trays V, which defines the so-called joint of the mosaic articles that can be obtained.
[0063] In particular, if the pitch between the tesserae T aligned along the sorting segment 9 is greater than the width of the separation distance between two contiguous compartments N, the pitch between the suction cups 55, once the tesserae T have been removed, is adjusted so as to adapt to said separation distance.
[0064] There are also vibrating means, for example of the pneumatic type, not shown, which are arranged proximate to the timed advancement segment 11 and are suitable to vibrate the trays V in order to facilitate the insertion and settling of the tesserae in the compartments N.
[0065] The output segment 13 is constituted by a bed of rollers 57, which is suitable to move away the filled trays V' toward subsequent processing stations, such as for example a station for bonding to the upward-facing laying surface of the tesserae T a binding sheet in order to obtain a mosaic article.
[0066] In practice it has been found that the described invention achieves the intended aim and objects.
[0067] It is noted that the machine according to the invention allows to make the filling of the trays an independent step that is not linked to the successive treatment steps; in particular, it allows to increase flexibility and improve the management of the subsequent bonding station.
[0068] The machine according to the invention in fact allows to feed the bonding station with trays that are prefilled with various kinds of tesserae, thus differentiating production, and to fully utilize the productivity of the bonding station, feeding it at full capacity.
[0069] The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the inventive concept.
[0071] In practice, the materials employed, as well as the shapes and the dimensions, may be any according to requirements without thereby abandoning the scope of the protection of the appended claims.
[0072] The disclosures in Italian Patent Application No. MO2002A000188 from which this application claims priority, are incorporated herein by reference.
[0073] Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.
1. A machine for filling trays with mosaic tesserae or the like, characterized in that it comprises a first continuous conveyor for conveying mosaic tesserae, a second
continuous conveyor for conveying trays for containing mosaic tesserae, and means
for transferring said tesserae from said first conveyor to said trays, which are movable
between said first and second continuous conveyors.
2. The machine according to claim 1, characterized in that it is functionally controlled by a programmable control and management unit.
3. The machine according to one or more of the preceding claims, characterized in that said first conveyor comprises a receiving segment, which is fed with said tesserae
and proximate to which there are means for orientating said tesserae T, said means
being suitable to arrange them so that their exposed face is directed toward said
first conveyor.
4. The machine according to one or more of the preceding claims, characterized in that said first conveyor comprises a segment for singling said tesserae.
5. The machine according to one or more of the preceding claims, characterized in that said first conveyor comprises a segment for sorting said tesserae so that they are
mutually spaced with a constant pitch, whose value can be preset, in at least one
row for feeding said transfer means.
6. The machine according to one or more of the preceding claims, characterized in that said singling segment is interposed between said receiving segment and said sorting
segment.
7. The machine according to one or more of the preceding claims, characterized in that said orientation means comprise means for sensing and recognizing the exposed face
or the laying face, or both, of said tesserae, said means being functionally coordinated
with means for overturning said tesserae, the tesserae being fed with either the exposed
face or the laying face directed toward said sensing means.
8. The machine according to one or more of the preceding claims, characterized in that said orientation means comprise a surface for the abutment of said tesserae that
runs substantially longitudinally above an input section of said receiving segment
and proximate to which there are said sensing means and said overturning means, the
tesserae being fed so that one side is directed toward said receiving segment and
being conveyed so that either their exposed face or their laying face is substantially
in contact with said abutment surface, the former overturning by gravity so that their
exposed face is directed toward said first conveyor proximate to the end edge of said
abutment surface, the latter overturning so that their exposed face is directed toward
said first conveyor by said overturning means.
9. The machine according to one or more of the preceding claims, characterized in that said sensing means comprise at least one optical sensor or the like.
10. The machine according to one or more of the preceding claims, characterized in that said overturning means comprise a blower duct, which is associated with air supply
means and is arranged so that its outlet is orientated substantially transversely
to said tesserae.
11. The machine according to one or more of the preceding claims, characterized in that said abutment surface is rendered movable concordantly with said receiving segment.
12. The machine according to one or more of the preceding claims, characterized in that said abutment surface comprises a belt, a ribbon or the like, which is closed in
a loop and wound around motorized pulleys, wheels or the like.
13. The machine according to one or more of the preceding claims, characterized in that said singling segment comprises two contoured shoulders which are arranged at an
adjustable distance from each other along the two opposite sides of said first conveyor
and form a guiding profile for the tesserae that is suitable to convey them individually
in a row along an advancement channel that is substantially as wide as said tesserae.
14. The machine according to one or more of the preceding claims, characterized in that said singling segment comprises an input portion, which is substantially co-planar
to said receiving segment, and an output portion, which is associated with means for
adjusting its inclination with respect to said input portion and said sorting segment,
the receiving segment and the sorting segment being arranged at different elevations
with respect to the horizontal plane.
15. The machine according to one or more of the preceding claims, characterized in that said output portion of said singling segment is constituted by a chute for the gravity
sliding of said tesserae.
16. The machine according to one or more of the preceding claims, characterized in that said sorting segment comprises a chain, a belt, a ribbon or the like, which is closed
in a loop and is wound around sprockets, pulleys, drums or the like, one of which
is a driving element, the others being driven, and is divided into a plurality of
transverse sections, in each of which there is a seat for containing a single tessera,
said seats being mutually spaced with a constant pitch whose value can be predefined
and adjusted.
17. The machine according to one or more of the preceding claims, characterized in that said second conveyor comprises a segment for the timed advancement of said trays
proximate to which said transfer means can move in order to fill the trays, the advancement
of said trays being functionally coordinated with the speed of said transfer means.
18. The machine according to one or more of the preceding claims, characterized in that said second conveyor comprises an input segment, which is fed with the empty trays
and is arranged upstream of said timed advancement segment with the interposition
of means for adjusting the feeding of the empty trays to the timed advancement segment.
19. The machine according to one or more of the preceding claims, characterized in that said second conveyor comprises an output portion that is arranged downstream of said
timed advancement segment in order to remove the trays filled with tesserae.
20. The machine according to one or more of the preceding claims, characterized in that said timed advancement segment comprises at least one bar for supporting said trays,
a chain, a belt, a ribbon or the like, which is closed in a loop and is wound around
sprockets, pulleys, drums or the like, one of which is associated with a motor of
the step type, the others being driven, and is arranged below said bar, and elements
for pushing said trays which are associated with said chain, belt, ribbon or the like
and are suitable to push said trays so that they advance along said bar.
21. The machine according to one or more of the preceding claims, characterized in that said input segment comprises a plurality of rollers for supporting said trays, which
are supported so that they can rotate freely and are mutually laterally adjacent so
that their longitudinal axes are substantially at right angles to the conveyance direction
of said trays, means for transmitting by traction the rotary motion to said rollers,
and motor means that are associated with said transmission means with the interposition
of engagement and disengagement means.
22. The machine according to one or more of the preceding claims, characterized in that said timed advancement segment comprises an input end and in that said input segment comprises an output end, said input end and output end being mutually
partially inserted in each other, said means for adjusting the supply of trays being
arranged proximate to said ends.
23. The machine according to one or more of the preceding claims, characterized in that said means for adjusting the feeding of the trays comprise a front retainer for the
empty tray to be filled and a rear separator for separating said empty tray to be
filled from the empty trays that follow it, said retainer and said separator being
associated with respective linear actuators that are suitable to actuate them alternately
and discordantly between respective active and inactive configurations.
24. The machine according to one or more of the preceding claims, characterized in that said transfer means comprise an automated handling unit, which is provided with means
for picking up said tesserae which are suitable to pick them from said first conveyor
and release them onto said trays.
25. The machine according to one or more of the preceding claims, characterized in that said picking means are constituted by a suction unit.
26. The machine according to one or more of the preceding claims, characterized in that said suction unit comprises at least one arm that is provided in a lower region with
at least one row of suction cups, which are associated with a suction circuit and
are mutually spaced with a constant pitch whose value can be predefined.
27. The machine according to one or more of the preceding claims, characterized in that said picking means comprise elements for adjusting the pitch of said suction cups.
28. The machine according to one or more of the preceding claims, characterized in that said trays comprise a supporting plate that is divided, in an upper region, into
a plurality of compartments for containing said tesserae, the pitch of the tesserae
aligned along said sorting segment and the pitch of said suction cups being substantially
equal to the distance that separates two contiguous compartments.
29. The machine according to one or more of the preceding claims, characterized in that it comprises vibrating means, which are arranged proximate to said timed advancement
segment and are suitable to vibrate said trays in order to facilitate the insertion
and settling of the tesserae in said compartments.
30. The machine according to one or more of the preceding claims, characterized in that said vibrating means are of the pneumatic type or the like.