Field of the invention
[0001] The present invention generally finds application in the field of stone working and
particularly relates to a method for surface working of items made of marble, granite,
cementitious agglomerates and other stone materials using water jets.
Background art
[0002] Methods are known for surface working of semi-finished products made of stone materials
or the like, such as slabs, blocks and the like, using one or more high-pressure and
high-speed liquid jets directed toward the surface of the products.
[0003] The high-pressure and high-speed jets operate by mechanical material surface removal,
to provide technical and/or aesthetic effects, such as abrasion, scratching, roughening,
scraping, marking or surface alterations according to particular designs and shapes.
[0004] Particularly, it is known to use plants having a multi-jet head located above the
surface of the product to be worked, which is moved in a plane substantially parallel
to the surface of the product being worked.
[0005] In order to obtain the mechanical material removal effect, the liquid of the jets
is generally mixed with suitable abrasives, preferably in powder form, which are propelled
at high speed against the surface to be worked.
[0006] Thus, the removal action is mainly caused by the abrasive material that is mixed
with the working liquid, which allows water feeding pressures to remain at relatively
low levels, also due to the additional abrasive action of the mechanical parts of
the pumps.
[0007] Furthermore, the use of abrasive materials involves a variety of problems, mainly
associated with the management of the abrasive material, that has to be stored and
recovered after use.
[0008] Also, during processing the particles of abrasive material should be prevented from
dispersing in the environment, as this might constitute a serious hazard for the operators
that control the apparatus.
[0009] Not the least, the abrasive material has a deteriorating effect on the parts of the
plant contacted thereby, particularly with the mixture feeding line, and with the
jet emitting nozzles.
[0010] Therefore, these prior art apparatus require frequent maintenance, involving downtimes
and throughput losses, as well as replacement of the parts under stress.
[0011] In order to obviate these drawbacks plants have been proposed for surface working
of products made of stone material that only use water jets, with no abrasive material
therein.
[0012] US 5,291,694 discloses an apparatus for surface working of slabs of stone materials, comprising
one or more multi-jet guns, each designed to emit a plurality of high-pressure water
jets to be directed to the surface to be worked. The jet emitting pressure, ranging
from 200 bar to 800 bar is inadequate to obtain a surface working effect with satisfactory
precision and definition. Indeed, this prior art apparatus is mainly used for finishing
of pre-processed surfaces.
[0013] A further drawback is that a single rotational and translational motion is imparted
to the nozzles, which causes repetitive and schematic reproduction of the working
patterns, thereby affecting the aesthetic value of the final product.
[0014] European Patent
EP1045742 discloses a further machine for fluid-jet surface working of stone products using
only water. In this machine, one or more water jets are emitted toward the surface
to be worked at an emission pressure ranging from 300 bar to 1500 bar. Nevertheless,
this solution also proved to be inadequate, as these water jet pressures affect jet
effectiveness and do not provide the desired surface effects.
[0015] Furthermore, also in this case, nozzles are displaced relative to the surface to
be worked with repetitive movements that create identical patterns typical of industrial
processing, with no random variation that would be characteristic of handmade products.
[0016] Not the least, the use of relatively low pressures requires operation at high flow
rates, with nozzles having relatively large outlet diameters. As a result, the cuts
that may be obtained rather coarse and do not afford the formation of fine designs.
Disclosure of the invention
[0017] The main object of this invention is to obviate the above drawbacks, by providing
a method for water jet surface working of products made of stone or the like that
is highly efficient and relatively cost-effective.
[0018] A particular object is to provide a method for surface working of products made of
stone materials that provides particularly distinct surface effects, reproducing the
effects of manual processing, only using water jets with no abrasive material therein.
[0019] Yet another object is to provide a method for surface working of products made of
stone materials, that can create any decorative pattern, possibly of figurative type,
or even texts, barcodes, QR codes, or the like, without particular limitation, and
with a single jet tool driving cycle.
[0020] A further object is to provide a method for surface working of products made of stone
materials, that affords high operational flexibility, with the possibility of changing
the surface texture even while the head is moving.
[0021] Another important object of the present invention is to provide a plant for surface
working of products made of stone materials that can provide multiple processing operations
of high aesthetic value.
[0022] These and other objects, as better explained hereafter, are fulfilled by a method
for surface working of semi-finished products, such as slabs made of a stone material
or the like, using liquid jets, which comprises the steps of providing a moving or
stationary support base for the products to be worked, providing a plurality of nozzles
for generating jets oriented toward such products for creating cuts on the product
being worked, forwardly moving the products relative to the nozzles in a longitudinal
direction.
[0023] The method is
characterized in that the nozzles are disposed in mutually offset positions in a transverse direction with
a predetermined pitch, and in that the projection of such pitch is continuously adjusted,
during operation, on a vertical plane substantially parallel to the transverse direction,,
to change the transverse distance between the longitudinal cuts made by the jets.
[0024] This particular combination of characteristics will allow the relative positions
of cuts to be changed to create a multiplicity of processing effects and obtain decorative
patterns that mimic manual operations, possibly figurative patterns.
[0025] Conveniently, the feeding pressure will be above 1500 bar to obtain an evident surface
cutting effect.
[0026] Advantageously, the nozzles may have an outlet with a maximum diameter ranging from
0.20 mm to 0.40 mm, preferably of about 0.30 mm.
[0027] Also, a step may be provided for selective adjustment of the impact pressure of jets
on such items being worked.
[0028] With this additional combination of characteristics, water jets of high strength
and high concentration may be directed to the surface, to act like a tool bit, to
form particularly sharp cuts.
[0029] Furthermore, the possibility of adjusting the impact pressure of the individual jets
allows the cutting action to be limited or locally omitted to create decorative patterns,
texts, codes and the like, at a high definition.
[0030] In a further aspect, the invention relates to a plant for abrasive-free liquid-jet
surface working of objects made of stone materials, as defined in claim 6.
[0031] Advantageous embodiments of the invention are defined in accordance with the dependent
claims.
Brief description of the drawings
[0032] Further features and advantages of the invention will be more apparent from the detailed
description of a preferred, non-exclusive embodiment of a plant according to the invention,
which is described as a non-limiting example with the help of the annexed drawings,
in which:
FIG. 1 is a top view of the plant of the invention;
FIG. 2 is a perspective view of the block that is part of the plant and comprises
the multi-jet head;
FIG. 3 is a front view of the block of Fig. 2;
FIG. 4 is a broken-away front view of the block of Fig. 2;
FIGS. 5 to 7 are bottom views of the block of Fig. 2 in three different operating
conditions;
FIG. 8 is a perspective view of a nozzle head that is part of the plant of the invention,
according to a first preferred configuration;
FIGS. 9 to 12 are views of a detail of the head of Fig. 8;
FIG. 13 is a sectional front view of the detail of Fig. 9;
FIG. 14 is a top view of the head of Fig. 8 in a particular operating mode;
FIGS. 15 and 16 are front views of the head of Fig. 8 in a second preferred configuration
and in two distinct operating conditions;
FIG. 17 is a side view of the head of Fig. 8 in a third operating configuration;
FIG. 18 is a side view of the head of Fig. 8 in a fourth operating configuration.
Detailed description of a few preferred embodiments
[0033] Referring to the above mentioned figures, a liquid jet plant of the invention, generally
designated by numeral 1, may be used for working items made of a hard material such
as stone, marble, granite or stone materials in general, cementitious materials, conglomerates
or the like, for surface working thereof.
[0034] The working process may be aimed at creating deformations on the surface S of an
item P, possibly caused by material removal, thereby forming a predetermined pattern
or texture, or an image, even a complex image. The item P may be in the form of a
slab, a block or have a not necessarily regular three-dimensional shape.
[0035] As shown in Fig. 1, the plant 1 comprises a moving or stationary support base 2 for
the items P to be worked and a head 3 facing the support base 2 and having a plurality
of nozzles 4, 4', 4", ... for generating jets J oriented toward the surface S of the
product P to be worked.
[0036] In the illustrated configuration, the support base 2 is stationary and has a substantially
horizontal orientation, such that the surface S to be worked may face upwards, the
head 3 being movable above the base 2. Nevertheless, the plant 1 can also process
inclined surfaces S, or surfaces lying on a support base that is inclined to the horizontal,
possibly even vertical.
[0037] The plant 1 also comprises feed means 5 for feeding the nozzles 4, 4', 4",... with
a high-pressure liquid, preferably water with no abrasive material therein, adapted
to generate high-pressure jets J to make cuts on the items P being worked.
[0038] While reference will be made herein, for simplicity, to a single nozzle, designated
with numeral 4, unless otherwise stated all the parts related to such nozzle 4 shall
apply in a substantially identical and operatively equivalent manner to the other
nozzles 4', 4",....
[0039] The head 3 is also associated with first drive means 6 for forward movement thereof
in a longitudinal direction X relative to the support base 2, and hence relative to
the items P thereon.
[0040] These first drive means 6 may be designed to longitudinally transfer the head 3 in
the longitudinal direction X, like in the illustrated configuration, and/or may be
associated with the support base 2, e.g. via a roller bed or a conveyor belt, for
longitudinally transferring the item P.
[0041] As more clearly shown in Figs. 2 and 12, according to a peculiar feature of the invention,
the nozzles 4 are mutually offset in a transverse direction Y with a predetermined
pitch p.
[0042] Furthermore, the plant comprises adjustment means 7 associated with the nozzles 4
for continuous adjustment of the projection of their pitch p on a vertical plane π
substantially parallel to the transverse direction Y during operation, to change the
transverse distance d between the longitudinal cuts made by the jets J.
[0043] Particularly, Figs. 2 to 5 show three different operating conditions, in which the
nozzles 4 are aligned in a direction W coplanar with the transverse direction Y but
inclined thereto at three different angles α,β,γ, to change their projection relative
to the vertical plane π.
[0044] Namely, in this configuration there will be a maximum distance d between cuts when
the direction of alignment W of the nozzles 4 is parallel to the transverse direction
Y and a minimum distance when it is orthogonal thereto, i.e. longitudinal. In this
case, cuts will substantially overlap.
[0045] According to a further particularly advantageous aspect of the invention, the feed
means 5 will be adapted to feed the working liquid at a minimum pressure above 1500
bar, with maximum values that may be continuously regulated without limitation, according
to the material to be worked and to the thickness of the item P, particularly when
the latter is a slab.
[0046] These feeding pressure values will provide the required definition of the cuts without
the use of abrasive materials, thereby eliminating all the drawbacks associated with
this operating condition.
[0047] In a particularly preferred embodiment, as shown in Fig. 1, the plant 1 comprises
a stationary load bearing structure 8 that surrounds the support base 2 and has a
pair of substantially longitudinal lateral shoulders 9.
[0048] The head 3 is supported by a substantially horizontal frame 10, as more clearly shown
in Figs. 2 to 7, which is in turn mounted to a substantially transversely oriented
beam 11, having opposite ends 12 that slide on respective longitudinal guides 13 associated
with corresponding shoulders 9.
[0049] The figures also show that the frame 10 supports two additional multi-jet heads 14,
15, disposed at the sides of the first head 3, which heads may be configured as taught
in Patent Applications
EP1977867 and
EP2105275 by the applicant hereof, and have nozzles, generally designated 16 and 17, disposed
on respective rotating plates 18 and 19, and connected to the feed means 5 of the
first head 3, which allows them to be fed at the above mentioned feeding pressures.
[0050] The two lateral heads 14, 15 are supported by the frame 10, to be integral with the
central head 2, such that they can follow its translational motion.
[0051] In this configuration, the first drive means 6 may be associated with the ends 12
of the beam 11 and may be of the carriage-driven type, allowing the longitudinal sliding
motion of the beam 11.
[0052] The latter may also have second drive means 20, also possibly of the carriage-driven
type, for imparting a longitudinal sliding motion to the frame 10 and hence to the
nozzle heads 2, 14 and 15, thereby allowing the working process to be also carried
out on surfaces S larger than the maximum transverse dimension of the head 2.
[0053] The plant 2 may further comprise electronic control means, not shown, which are adapted
to interpolate the movements imparted by the first drive means 6 and the second drive
means 20 and by the adjustment means 7, as well as any other movement as described
hereinbelow, to obtain complex motions of the head 2.
[0054] The central head 2 comprises an elongate body 21 mainly extending in the direction
L, with the nozzles 4 being mounted thereto in mutually offset positions and with
jets J oriented toward the products being worked.
[0055] As more clearly shown in Figs. 8 to 12, the elongate body 21 is fixed to a support
shaft 22, that is pivotally mounted to the horizontal frame 10 to rotate about an
axis of rotation R that is substantially perpendicular to the elongate body 21.
[0056] As more clearly shown in Fig. 13, the feed means 5 may comprise a feed line 23 which
is disposed at the periphery of the shaft 22, and is connected to a distribution channel
24 formed in the head 3 and connected to the nozzles 4.
[0057] The adjustment means 7 may act on the rotating shaft 22 to promote its rotation about
the axis of rotation R, which will change the projection of the pitch p and the relative
distance d between cuts. Furthermore, they may be designed to also allow the shaft
22 to rotate by 360°, as schematically shown in Fig. 14.
[0058] The rotation of the shaft 22 during processing may be either continuous or discrete,
such that corrugated, helical or other complex cuts may be formed without stopping
the plant 1.
[0059] Nevertheless, the angular orientation of the head 2 with respect to the transverse
direction Y may be also obtained in a non-dynamic manner, i.e. by inclining the elongate
body 2 relative to the transverse direction Y at an angle that is kept constant during
processing.
[0060] In an alternative configuration, as shown in Figs. 15 and 16, the nozzles 4 are mounted
to the head 3 via respective sections 25 that are movable relative to the elongate
body 21 along its main extension axis L.
[0061] The adjustment means 7 comprise third drive means 26 which act on the sections 25
to change their mutual distance along the extension axis L, thereby adjusting the
projection of the nozzles 4 on the vertical transverse plane π and hence the transverse
distance d between cuts.
[0062] The third drive means 26 in turn comprise interface means 27 for selectively actuating
each section 25 relative to the others and changing the relative distance between
at least one pair of nozzles 4. The interface means 27 may be of mechanical type,
i.e. a rack, or of electromechanical or electronic type or the like, without limitation.
[0063] Furthermore, in both configurations of Fig. 8 and Fig. 14, the adjustment means 7
may comprise fourth drive means 28 for imparting an inclination χ to the axis of rotation
R relative to the vertical, to change the distance of the nozzles from the support
base 2. The fourth drive means 28 may be associated directly with the head or with
the rotating shaft 22 or the frame 10.
[0064] In a particularly advantageous configuration, the nozzles 4 of the central head 3
may have an outlet 29 with a maximum diameter φ preferably ranging from 0,15mm to
0,60 mm and more preferably from 0,20 mm to 0,40 mm, e.g. of about 0,30 mm, to obtain
jets J of small sizes. The outlets 29 may be of any shape, e.g. of circular, elliptical,
square, rectangular, polygonal or the like shape, without limitation, to obtain cuts
of various shapes.
[0065] Furthermore, pressure regulator means 30 may be provided, for selective adjustment
of the impact pressure of jets J on the items P being worked. The pressure regulator
means 30 are conveniently associated with electronic control means, not shown, for
selective interaction of the pressure regulator means 30 with the nozzles 4, such
that the intensity of the individual jets J may be adjusted independently of one another.
[0066] This additional feature, as well as the relatively small size of the out flowing
jets J will allow not only abstract decorative patterns, but also figurative patterns,
text, barcodes, QR codes and the like, to be formed on the surface S being worked.
[0067] In a first embodiment, as shown in Fig. 17, the pressure regulator means 30 comprise
deflector members 31 located downstream from each nozzle 4 to intercept the jet J
and change the impact force on the surface S to be worked.
[0068] The deflector members 31 may be of mechanical or electromechanical type and comprise
a plate 32, which is designed to move between an inoperative position, external to
the relevant jet J and an operative position in which the plate 32 at least partially
faces the outlet 29 of the corresponding nozzle 4, to at least partially intercept
its jet J and reduce or substantially eliminate its impact pressure.
[0069] In an alternative configuration, not shown, the deflector members may be of the compressed-air
type, with respective nozzles arranged at the water jet nozzles 4, to blow a high-speed
air flow to the jets J for deflecting them, such that they will not impact the surface
S or will impact it at a reduced pressure that will not cause scratching thereof.
[0070] In yet another alternative configuration, also not shown, the pressure regulator
means 30 may be associated with the feed means 5 and comprise a plurality of electronically
controlled valves operatively connected to each nozzle 4 for selective adjustment
of their feeding pressure.
[0071] Furthermore, the feed means 5 may be adapted to impart an electric charge of predetermined
polarity to the water to be fed to the nozzles 4, and the pressure regulator means
30 may be in turn adapted to generate an electric or electromagnetic field at the
nozzles 4, for deflecting the electrically charged jet J.
[0072] For example, the feed means 5 may be designed to charge the water to be fed to the
nozzles 4 with a polarizing substance, such as an appropriately charged salt, which
is adapted to interact with the downstream generated field to create a repulsive electric
or electromagnetic force.
[0073] Advantageously, the feed means 5 may be designed to draw the abrasive-free water
of the emitted jets J and recirculate it for reuse and convey it, possibly after filtration,
to the nozzles 4, thereby defining a closed loop.
[0074] In yet another aspect of the invention, the pressure regulator means 30 may comprise
fifth drive means, not shown, for selectively rotating the elongate body 21 about
its main extension axis L and/or one or more of the nozzles 4, as schematically shown
in Fig. 18, thereby allowing the jets J to be inclined to the vertical.
[0075] This configuration is particularly advantageous, as the jets J may be inclined to
operate in the same direction as the longitudinal transfer direction X of the head
3, or in a direction opposite thereto, thereby further increasing the operativity
of the plant 1.
[0076] All the above mentioned drive means may include mechanical, electromechanical, hydraulic,
oil-hydraulic, pneumatic, manual or automated actuators or the like, possibly controllable
in an independent manner, and with procedures that are typical for this type of plants,
and known to those skilled in the art, that will not have to be described herein in
further detail.
[0077] The invention also provides a method for liquid-jet surface working of items P made
of a stone material or the like, that can be carried out, without limitation, using
the above mentioned plant 1.
[0078] The method basically comprises a step a) of providing a moving or stationary support
base for the items to be worked, a step b) of providing a plurality of nozzles for
generating jets oriented toward the items to be worked, a step c) of feeding the nozzles
with a high-pressure liquid adapted to create cuts on the items being worked, a step
d) of forwardly moving the items relative to the head in the longitudinal direction,
a step e) in which the relative positions of the nozzles are staggered in a transverse
direction with a predetermined pitch, and the projection of their pitch is continuously
adjusted on a vertical plane substantially parallel to a transverse direction, to
change the transverse distance between the longitudinal cuts made by the jets.
[0079] Conveniently, the step c) of feeding the jets comprises feeding only water, without
using abrasives, at a feeding pressure above 1500 bar.
[0080] The method may also comprise one or more additional steps of controlled displacement
of the jets in one or more directions of translation and/or rotation, and a step of
selective regulation of the impact pressure of jets, for carrying out all the operations
as described above for the plant.
[0081] Particularly, the step e) of adjusting the pitch p of the nozzles 4 may comprise
a step f) of joined rotation of the nozzles 4 about an axis of rotation R substantially
orthogonal to the support base 2.
[0082] Alternatively, the pitch p may be adjusted by mutually transferring the nozzles 4
parallel to the transverse direction Y, possibly but not necessarily combining the
above mentioned joined rotation about the axis R.
[0083] Furthermore, a step g) may be provided of selectively regulating the impact pressure
of the jets J on the items P being worked, said step being carried out by deflecting
the individual jets J such that they do not impact the surface S being worked or impact
it with not enough energy to deform the material and/or by selectively stopping water
feeding to the individual nozzles 4.
[0084] Furthermore, a step h) may be provided of inclining the jets J relative to the vertical
to selectively change their distance from the support base 2.
[0085] Not the least, a step i) may be provided for recovering the feeding water of the
emitted jets to recirculate and reuse it for feeding the nozzles 4, possibly after
filtration, thereby creating a closed loop.
[0086] Thus, the use of simple water as a working fluid will not only ensure environmental
friendliness of the method, but also provide the additional cost-saving advantage.
[0087] The above disclosure clearly shows that the plant and method of the invention fulfill
the intended objects and particularly meet the requirement of allowing the formation
of a multiplicity of well-defined decorative patterns on the surface of the item,
which patterns may be of either abstract or figurative type, or possibly consist of
text, barcodes, QR codes or the like.
[0088] The plant and method of the invention are susceptible to a number of changes or variants,
within the inventive concept disclosed in the appended claims. All the details thereof
may be replaced by other technically equivalent parts, and the materials may vary
depending on different needs, without departure from the scope of the invention.
[0089] While the plant and method have been described with particular reference to the accompanying
figures, the numerals referred to in the disclosure and claims are only used for the
sake of a better intelligibility of the invention and shall not be intended to limit
the claimed scope in any manner.
1. Method for surface working of semi-finished products made of stone or the like base
material using abrasive-free liquids jets, comprising the following steps:
a) providing a moving or stationary support base (2) for the products (P) to be worked;
b) providing a plurality of nozzles (4, 4', 4",...) for generating jets (J) oriented
toward the products (P) being worked;
c) feeding said nozzles (4, 4', 4",...) with a high pressure liquid adapted to create
cuts on the products (P) being worked;
d) moving the products (P) relative to said nozzles (4, 4', 4",...) in a longitudinal
direction (X);
characterized in that said nozzles (4, 4', 4",...) are arranged in mutually offset positions (e) in a transverse
direction (Y) with a predetermined pitch (p) and in that the projection of their pitch (p) is continuously adjusted on a vertical plane (π)
substantially parallel to said transverse direction (Y) during operation to change
the transverse distance (d) between the longitudinal cuts of said jets (J).
2. Method as claimed in claim 1, wherein said pressure is higher than 1500bar.
3. Method as claimed 1 or 2, wherein said step (e) of adjusting the pitch (p) comprises
a step (f) of rotating said nozzles about a rotation axis (R) substantially orthogonal
to said support base (2).
4. Method as claimed in claim 1, wherein step (g) is provided for selectively adjusting
the impact pressure of the jets (J) on the products (P) being worked.
5. Method as claimed in claim 1, wherein a step (h) is provided for inclining said jets
(J) with respect to the vertical direction for selectively changing the distance thereof
from said support base (2).
6. A plant for surface working products made of stony or the like base material with
jets of abrasive-free liquids, comprising:
- a movable or stationary support base (2) for an product (P) to be worked;
- a head (3) facing said support plane (2) and provided with a plurality of nozzles
(4, 4', 4",...) for generating jets (J) oriented toward the surface of the product
(P) being worked;
- feed means (5) for feeding said nozzles (4, 4', 4",...) with a high pressure liquid
adapted to generate cuts on the product (P) being worked;
- first drive means (6) for moving of the product (P) relative to said head (3) in
a longitudinal direction (X);
characterized in that said nozzles (4, 4', 4",...) are mutually offset in a transverse direction (Y) with
a predetermined pitch (p), adjustment means (7) being associated with said nozzles
(4, 4', 4",...) to continuously adjust the projection of their pitch (p) in a vertical
plane (π) substantially parallel to said transverse direction (Y) during operation,
in such a manner to change the transverse distance (d) between the longitudinal cuts
of said jets (J).
7. Plant as claimed in claim 6, wherein regulation means (30) are provided to selectively
adjust the impact pressure of the jets (J) on the products (P) being worked, said
regulation means (30) comprising flow deflector members (31) placed downstream of
each nozzles (4, 4', 4",...) to partially intercept the jet (J) and change the impact
force acting on the surface (S) being worked, said flow deflector members (31) being
selected between the group comprising mechanical deflectors, compressed air deflectors
or the like.
8. Plant as claimed in claim 7, wherein said regulation means (30) are associated with
said feed means (5) and comprise a plurality of solenoid valve operatively connected
with each of said nozzles (4, 4', 4",...) to selectively adjust the feeding pressure
thereof.
9. Plant as claimed in claim 7, wherein said feed means (5) are adapted to impact an
electric charge of a predetermined polarity to the water to be fed to said nozzles
(4, 4', 4",...), said regulation means (30) being adapted to generate in said nozzles
(4, 4', 4",...) an electric field adapted to deflect the electrically charged jets
(J).
10. Plant as claimed in claim 7, wherein said head (3) comprises an elongate body (21)
on which said nozzles (4, 4', 4",...) are mounted in mutually offset positions and
with jets (J) oriented toward the products (P) being worked, said regulation means
(30) comprising drive means for selectively rotating said elongate body (21) about
its longitudinal extending axis (L) and/or one or more of said nozzles (4, 4', 4",...)
in such a manner to promote the inclination of the jets (J) with respect to the vertical
direction.