GLAZING ISLAND

Abstract

 A glazing island (1) for slab-shaped semi-finished products (2) having an upper surface (S), comprising:
- a conveyor line (L), comprising a conveyor surface (3) that is movable along a conveyance direction (X), wherein the conveyor line (L) comprises two distinct branches (Li);
- a final glazing station (4), adapted to deposit a covering substance on the upper surface (S) of the slab-shaped semi-finished products (2) moved by the conveyor surface (3) along the conveyor line (L),
wherein the final glazing station (4) comprises at least two dispensing devices (5), distinct and independent from each other, wherein each dispensing device (5) is located on a branch (Li) of the conveyor line (L) and is adapted to deposit a covering substance on the upper surface (S) of the slab-shaped semi-finished products (2) moved by the conveyor surface (3) along that branch (Li) of the conveyor line (L).
A production plant (10) comprising the glazing island (1).

Description

[0001] The present invention relates to a glazing island.

[0002] The glazing island has advantageous application in the sector of decoration of slab-shaped semi-finished products, in particular slab-shaped semi-finished products of the ceramic type, without, however, excluding other sectors of application.

[0003] In the sector of decoration of ceramic semi-finished products, it is possible to identify glazing lines adapted to receive as input semi-finished products coming from a press and to decorate them by depositing one or more layers of different substances.

[0004] Glazing lines thus provide for one or more successive stations, each adapted for the deposition of a substance to form a layer on the semi-finished product: typically, glazing lines provide, firstly, for the deposition of a base, intended to cover any chromatic and structural inhomogeneities; then follows a step of decorating with coloured inks in order to reproduce a desired decorative pattern using one of the techniques known in the sector. Lastly, a final glazing step is carried out to deposit a covering element that represents the outermost surface of the finished product.

[0005] Together, the base, decoration and covering substance deposited on the surface of the semi-finished product are also called the surface finish of the semi-finished products.

[0006] Depending on the type of base, decoration and covering substance, the finished product will take on different appearances, as well as different structural and surface properties, such as impermeability and wear and corrosion resistance.

[0007] In other words, different surface finishes obtained by depositing different types of materials and/or using different techniques allow finished products having different characteristics to be obtained.

[0008] Within a production plant, the glazing line is used to produce one type of finished product at a time, so as to form a homogeneous batch of finished products. In other words, after the type of finished product it is intended to produce has been selected, the glazing stations are loaded with the substances and raw materials necessary to obtain each layer forming the selected surface finish; then the glazing process is started by depositing, in an orderly fashion, the layers on a plurality of semi-finished products conveyed through the glazing stations.

[0009] In order to produce a different type of finished product or, in other words, to make a different batch, the glazing stations must be shut down, cleaned and loaded with new materials and components, corresponding to the new surface finish desired. This process, essential to prevent undesirable contaminations between batches, requires a considerable amount of time and employs dedicated tools and operators.

[0010] The main limit of the prior art, therefore, is that traditional glazing lines cause wastes of time that translate into economic losses within a production line, such wastes and such losses being determined by the above-described interruption of the glazing line which necessarily separates the glazing of different batches of finished products.

[0011] A further limit of the prior art is that the glazing lines lack versatility and efficiency, even if it is desired to replace only one of the layers deposited by the glazing line: for example, if one wished to obtain a matt finish to replace a glossy finish, the base and decoration being the same, this choice would nonetheless entail the interruption of the process in order to replace the glossy covering substance with a matt covering substance.

[0012] Therefore, even in the case of similar finished products, the glazing lines as per the prior art are subject to production slowdowns and, therefore, losses in economic terms, compared to a continuous operation.

[0013] Finally, repeated switching on and off of the glazing stations results in considerable energy consumption, greater than with a continuous operation of the same.

[0014] Alternatively, in the prior art there are production plants comprising a plurality of independent glazing lines, each dedicated to the production of a finished product: in other words, every glazing line within production plants completes a glazing process on a homogeneous batch of finished products, depositing a base, a decoration and a covering layer on semi-finished products conveyed along a given line. In order to obtain two or more finished different products simultaneously, it is necessary to install two or more independent glazing lines within the production plant, each line comprising all the machinery and devices necessary to complete the glazing operations.

[0015] As a consequence, the production plants as per the prior art have the evident limit of having to rely on a large number of machines in order to be able to simultaneously produce different finished products.

[0016] A limit of the production plants as per the prior art, therefore, is a high rigidity and low production versatility determined by the aforesaid independent production lines.

[0017] In addition, a further limit of the prior art is that a large number of machines requires a large amount of energy in order to maintain production active.

[0018] Every production line, moreover, being independent of the others, if affected by malfunctions or undergoing maintenance must necessarily be interrupted for the time necessary to complete repair and maintenance operations; consequently, production must be interrupted or greatly slowed for that necessary time. A further evident limit of the prior art, therefore, is that production plants comprising independent lines are subject to wastes in terms of time, which translate into losses from an economic standpoint.

[0019] The object of the present invention is to provide a glazing island capable of overcoming the evident limits of the prior art, thus improving the versatility and efficiency of the glazing process.

[0020] Additional features and advantages of the present invention will become more apparent from the detailed description that follows of one embodiment of the invention in question, illustrated by way of non-limiting example in the appended figures, in which:

• figure 1 shows a schematic representation of a glazing island according to the present invention in the preferred embodiment;
• figure 2 shows a schematic representation of a production plant according to the present invention, comprising the glazing island;
• figure 3 shows a top view of the production plant in figure 2, in the preferred embodiment of the present invention.

[0021] The subject matter of the present invention thus relates to a glazing island 1 for slab-shaped semi-finished products 2. The slab-shaped semi-finished products 2 have an upper surface S, a lower surface and a plurality of lateral sides, wherein the distance between the upper surface S and lower surface is less than the distance between lateral sides. However, semi-finished products having different three-dimensional structures are not excluded, provided that they have the aforesaid upper surface S.

[0022] Preferably, but not exclusively, the slab-shaped semi-finished products 2 are of the ceramic type.

[0023] The glazing island 1 according to the present invention comprises a conveyor line L, comprising a conveyor surface 3 that is movable along a conveyance direction X; the conveyor surface 3, connected to handling means of the type known to the sector, is adapted to receive, resting thereon, the lower surface of the slab-shaped semi-finished products 2 and to move the slab-shaped semi-finished products 2 in the conveyance direction X, through the glazing island 1.

[0024] In other words, the slab-shaped semi-finished products 2, situated in storage magazines or coming from processing stations located upstream of the glazing island 1, are conveyed along the conveyor line L by the conveyor surface 3 through the glazing island 1.

[0025] The glazing island 1 according to the present invention comprises a final glazing station 4, adapted to deposit a covering substance on the upper surface S of the slab-shaped semi-finished products 2 moved by the conveyor surface 3. The covering substance will be better defined below.

[0026] The slab-shaped semi-finished products 2 entering the glazing island 1 typically have an upper surface S which is porous, permeable and easily damaged by chemical agents: with the aim of imparting greater surface resistance and increasing the level of impermeability, the final glazing station 4 is adapted to deposit the aforesaid covering substance on the upper surface S.

[0027] In detail, the final glazing station 4 comprises at least two dispensing devices 5, each located on a branch Li of the conveyor line L. In other words, in the conveyor line L, the movable surface 3 is adapted to move each slab-shaped semi-finished product 2 towards a dispensing device 5 through the respective branch Li. In still other words, the branches Li represent ramifications of the conveyor line L, adapted to enable each slab-shaped semi-finished product 2 to reach one of the dispensing devices 5.

[0028] The branches Li of the conveyor line L are thus distinct and independent from each other: each slab-shaped semi-finished product 2 is conveyed by the movable surface 3 towards the dispensing device 5 adapted to dispense the covering substance imparting desired characteristics to the slab-shaped semi-finished product 2 or to a batch of slab-shaped semi-finished products 2 (figure 1).

[0029] At the end of dispensing of the covering substance, the slab-shaped semi-finished products 2 are conveyed by the conveyor surface 3 along the respective branch Li; preferably, the branches Li going out from each final glazing station 5 converge in a common branch Lc. The common branch Lc is adapted to bring about the conveyance of the slab-shaped semi-finished products 2 towards a subsequent production island: at said subsequent production island, the common branch Lc can be divided again into two or more branches Li.

[0030] Considering the dispensing devices 5 in detail, each of them is adapted to deposit, on the upper surface S, a covering substance suitable for imparting to the slab-shaped semi-finished product 2 and, in particular, to the upper surface S thereof, aesthetic characteristics, such as gloss or, by contrast, opaqueness, and/or mechanical properties, such as wear and corrosion resistance and impermeability.

[0031] Such characteristics are preferably, but not exclusively, achieved and consolidated at the end of a firing step carried out in a kiln 13 located downstream of the glazing island 1, considering the conveyance direction X. However, such characteristics can also be directly obtained at the end of the dispensing step.

[0032] Different types of covering substances impart different aesthetic characteristics and/or mechanical properties to the slab-shaped semi-finished product 2 and, in particular, to the upper surface S thereof.

[0033] Covering substances adapted to impart different characteristics and properties to the slab-shaped semi-finished product 2 are also not excluded, such characteristics being known to the person skilled in the art. For example, but not exclusively, the covering substance can comprise vitreous components which vitrify once subjected to firing, thus imparting an improved impermeability to the upper surface S; additionally or alternatively, the covering substance can comprise grit and/or glazes which, at the end of the aforesaid firing step, impart an improved wear and corrosion resistance and a glossy appearance to the slab-shaped semi-finished product 2. Alternatively, the covering substance can comprise additives and opacifiers, adapted to impart an opaque or matt appearance to the upper surface S. Additionally, or alternatively, the covering substance can comprise one or more pigments and colouring oxides, which impart desired chromatic characteristics to the upper surface S. Other compounds can be comprised in the covering substance.

[0034] Within the final glazing station 4, the preferred but not exclusive type of dispenser 5 of the covering substance is illustrated in patent application 102020000031547 in the name of the same applicant.

[0035] Advantageously, in the final glazing station 4 each dispensing device 5 can be adapted to dispense a respective covering substance, differing from the covering substances dispensed by other dispensing devices 5.

[0036] A technical advantage achieved compared to the prior art is the glazing island 1 according to the present invention, thanks to the presence of dispensing devices 5 located on distinct and independent branches Li, which allows different types of finished slab-shaped products 2f to be obtained from the slab-shaped semi-finished products 2 as input to the final glazing island 4; the finished slab-shaped products 2f correspond to different batches, which are produced simultaneously.

[0037] In fact, in a first embodiment, the glazing island 1 comprises a final glazing station 4 having one dispensing device 5 supplied with raw materials adapted to form a glossy covering layer and a second dispensing device 5 supplied with raw materials adapted to form a matt covering layer. Advantageously, the glazing island 1 according to the present invention allows for simultaneously producing batches of finished slab-shaped products 2f having a glossy covering layer and batches of finished slab-shaped products 2f having a matt covering layer, while avoiding having to interrupt the production line between the production of the aforesaid batches.

[0038] Advantageously, the glazing island 1 makes it possible to avoid, or in any case reduce, the cleaning operations necessary to enable the passage from the production of one batch to the production of a different batch. Advantageously, the production times are reduced and the process is more versatile and efficient.

[0039] In a second embodiment, the glazing island 1 comprises a final glazing station 4 having several glazing devices 5 adapted to dispense the same covering substance: a technical advantage achieved compared to the prior art is that it is possible to carry out routine and extraordinary maintenance operations by isolating one glazing device 5 at a time and, therefore, interrupting one branch Li at a time; the slab-shaped semi-finished products 2 are thus advantageously diverted towards the glazing device 5 or the glazing devices 5 that are running, without completely interrupting the conveyor line L.

[0040] Advantageously, the glazing island 1 according to the present invention makes it possible to reduce the impact in terms of time and costs deriving from malfunctions and maintenance operations.

[0041] Intuitively, different configurations can be adopted for the branches Li of the conveyor line L and for the dispensing devices 5 of the final glazing station 4.

[0042] The glazing island 1, in an alternative embodiment, comprises a decorating station 6, adapted to produce a decoration on the slab-shaped semi-finished products 2. Preferably, the decorating station 6 is located upstream of the final glazing station 4 relative to the conveyance direction X, enabling a decoration to be produced on the upper surface S before the covering substance is deposited (figure 1).

[0043] Alternatively, the decorating station 6 can be located downstream of the final glazing station 4: in this case, the decorating station 6 enables a decoration to be produced on top of the covering substance; in this configuration it is possible to exploit for example, but not exclusively, so-called overglaze decoration techniques.

[0044] The term decoration means a wide variety of patterns and motifs produced with elements such as inks and glazes deposited on the upper surface S using decorating techniques known to the sector, typically comprising ink-jet printing. Elements, materials and decorating techniques other than the ones mentioned, but which the person skilled in the art is intuitively able to identify, are not excluded.

[0045] The decorating station 6 comprises one or more decorating devices 7, each adapted to produce a decoration on the slab-shaped semi-finished products 2. In other words, the slab-shaped semi-finished products 2 are moved by the conveyor surface 3 of the conveyor line L towards one of the decorating devices 7; in detail, each slab-shaped semi-finished product 2 is conveyed along one of the branches Li of the conveyor line L towards the decorating device 7 adapted to produce the respective decoration; this decoration is preferably different for each batch of finished slab-shaped products 2f.

[0046] In a first embodiment, the glazing island 1 comprises a decorating station 6 having decorating devices 7 adapted to produce various types of decoration: in other words, each decorating device 7 is adapted to produce a different decoration using different elements, materials and/or application techniques.

[0047] Advantageously, therefore, the glazing island 1 according to the present invention allows different batches of finished slab-shaped products 2f to be completed simultaneously, by applying a different decoration by means of each decorating device 7.

[0048] As a consequence, it is not necessary to interrupt the conveyor line L between the decoration of one batch and the decoration of the next batch in order to change the decorative elements and materials and/or decoration technique: in this manner, the production of different batches of finished slab-shaped products 2f is made more rapid and efficient and the wastes of time and economic losses related to the time necessary to replace of materials and/or change the decoration technique are advantageously reduced.

[0049] In a second embodiment, the glazing island 1 comprises a decorating station 6 having two or more decorating devices 7 adapted to produce the same decoration on the slab-shaped semi-finished products 2.

[0050] A technical advantage achieved compared to the prior art is that, similarly to what was affirmed for the final glazing station 4, it is possible to carry out cleaning and routine and extraordinary maintenance operations without completely interrupting the conveyor line L through the decorating station 6.

[0051] Advantageously, therefore, the glazing island 1 according to the present invention comprising the decorating station 6 makes it possible to reduce the impact in terms of time and in economic terms deriving from malfunctions and maintenance operations on the decorating devices 7.

[0052] Intuitively, various configurations can be adopted for the branches Li of the conveyor line L and for the decorating devices 7 of the decorating station 6.

[0053] Preferably, the branches Li going out from the decorating station 6 converge in a common branch Lc, along which the slab-shaped semi-finished products 2 are conveyed until reaching the final glazing station 4, where the common branch Lc is again divided into the branches Li, each dedicated to dispensing the respective covering substance.

[0054] In a further embodiment, the glazing island 1 comprises a base glazing station 8, adapted to apply a base on the slab-shaped semi-finished products 2. Preferably, the base glazing station 8 is situated upstream of the final glazing station 4 relative to the conveyance direction X; preferably, the base application station 8 is located upstream of the decorating station 6 considering the conveyance direction X (figure 1).

[0055] The term base means a covering compound, preferably adapted to cover any structural or chromatic inhomogeneities present on the upper surface S of the slab-shaped semi-finished product 2. Moreover, the application of the base allows the decoration subsequently applied by the decorating station 6 and/or the covering substance dispensed by the final glazing station 4 to stand out more distinctly.

[0056] Non-exclusive examples of a base, known to the person skilled in the art, are engobes, smaltobbi (highly vitrified engobes) and glazes; different bases have different formulations in terms of components, thus determining a different final yield in terms of coverage and in chromatic terms.

[0057] Moreover, there are numerous techniques for applying the base. For example, but not exclusively, the base can be applied by spraying on the upper surface S.

[0058] The base glazing station 8 comprises one or more base applicators 9, each adapted to dispense or apply the base on the slab-shaped semi-finished products 2. In other words, the slab-shaped semi-finished products 2 are moved by the conveyor surface 3 of the conveyor line L towards one of the base applicators 9; in detail, each slab-shaped semi-finished product 2 is conveyed along one of the branches Li of the conveyor line L towards the base applicator 9 adapted to dispense the respective base; the base is preferably, but not exclusively, different for every batch of finished slab-shaped products 2f.

[0059] In a first embodiment, the glazing island 1 comprises a base glazing station 8 having base applicators 9 adapted to dispense various types of base: in other words, each base application device 9 is adapted to dispense a different type of base using different materials and/or application techniques.

[0060] Advantageously, in this case as well, the glazing island 1 according to the present invention, comprising the base glazing station 8, allows different batches to be produced simultaneously by applying a different base by means of each base applicator 9, thereby determining the production of different finished slab-shaped products 2f.

[0061] As a consequence, it is not necessary to interrupt the conveyor line L in order to change the type of base to be applied on the slab-shaped semi-finished products 2, thus making the production of different batches more rapid and efficient and reducing the wastes in terms of time and economic wastes caused by replacements of the base between different batches and the cleaning of materials to avoid contaminations between different bases.

[0062] In a second embodiment, the glazing island 1 comprises a base glazing station 8 having base applicators 9 adapted to dispense the same base on the slab-shaped semi-finished products 2.

[0063] A technical advantage achieved compared to the prior art is that, similarly to what was affirmed for the final glazing station 4 and for the decorating station 6, it is possible to carry out cleaning and routine and extraordinary maintenance operations without completely interrupting the conveyor line L.

[0064] Advantageously, therefore, the glazing island 1 according to the present invention comprising the base glazing station 8 makes it possible to reduce the impact in terms of time and in economic terms deriving from malfunctions and maintenance operations on the base applicators 9.

[0065] Intuitively, different configurations can be adopted for the branches Li of the conveyor line L and for the base applicators 9 of the base glazing station 8.

[0066] Similarly to what was affirmed previously, the branches Li going out from base glazing station 8 also converge into a common branch Lc, through which the slab-shaped semi-finished products 2 are conveyed towards the decorating station 6.

[0067] The above-described base glazing station 8, decorating station 6 and final glazing station 4 can be differently positioned along the conveyor line L in order to obtain particular surface finishes on the slab-shaped semi-finished products 2. Moreover, more than one base glazing station 8 and/or more than one decorating station 6 and/or more than one final glazing station 4 can be installed on the conveyor line L in order to obtain more complex surface finishes on the slab-shaped semi-finished products L.

[0068] In the preferred but not exclusive embodiment illustrated in figure 1, the glazing island 1 comprises a base glazing station 8 comprising two base applicators 9 for applying two different bases, each located on the respective branch Li. A common branch Lc connects the base glazing station 8 to the decorating station 6 located downstream of the previous one according to the conveyance direction X: the decorating station 6 comprises three decorating devices 7, each configured to operate independently of the others. The decorating devices 7 are preferably digital ink-jet printers.

[0069] Advantageously, the presence of decorating devices 7 in greater number than the base applicators 9 makes it possible to produce complex decorations requiring a considerable amount of time, without slowing the production speed. In fact, while on the one hand dispensing of the base typically takes place in a short time, on the other hand producing the decoration requires a longer time the larger the number of inks used and the more complex the decoration to be produced. With the aim of limiting or avoiding slowdowns in production, the glazing island 1 according to the preferred embodiment comprises a larger number of decorating devices 7 than base applicators 9.

[0070] Finally, a further common branch Lc connects the decorating station 6 to the final glazing station 4: preferably, the final glazing station 4 comprises two dispensing devices 5, one adapted to dispense a glossy covering substance and one adapted to dispense a matt covering substance. Furthermore, in the preferred embodiment, the glazing island 1 comprises a further dispensing device 5, three further decorating devices 7 and two further final glazing stations 4, which are redundant with respect to the others and can be activated in the event of production needs (figure 3).

[0071] Advantageously, thanks to the branches Li and the common branches Lc described above, the slab-shaped semi-finished products 2 are not rigidly constrained to one decoration line, but can pass through the base glazing station 8, decorating station 6 and final glazing station 4 following a plurality of different paths given by the combination of branches Li subsequently followed. In a highly advantageous manner, it is possible to obtain a large number of combinations of bases, decorations and covering substances without relying on a large number of independent lines or a large number of machines. In a highly advantageous manner, it is possible to obtain a large number of combinations of bases, decorations and covering substances simultaneously. In other words, it is possible to simultaneously produce different batches of finished slab-shaped products 2f.

[0072] Therefore, according to the batch of finished slab-shaped products 2f it is intended to obtain, the slab-shaped semi-finished products 2 can receive one or more of the base, decoration and covering substance in order to obtain the desired surface finish for each batch.

[0073] The glazing island according to the present invention further comprises a control system, adapted to detect the presence of the slab-shaped semi-finished products 2 and to determine the appropriate surface finish thereof according to the batch or batches it is intended to obtain.

[0074] In detail, the glazing island 1 comprises one or more detection sensors V, adapted to detect parameters of interest relating to each semi-finished product 2; in other words, the detection sensors V are configured to detect at least one parameter of interest, such as shape, size, surface characteristics, or other parameters characterising the slab-shaped semi-finished product 2 and to send such parameters to the control system; the control system, on the basis of the parameters received from the detection sensors V, sends operating commands to actuators adapted to move the slab-shaped semi-finished product 2 along the correct branch Li of the conveyor line L.

[0075] In detail, the detection sensors V, communicating with the control system of the glazing island 1, are preferably located at the entry of the glazing island in order to detect the presence of semi-finished products 2 conveyed by the conveyor surface 3; further detection sensors V can be located between the base application station 8 and the decorating station 6 and/or between the decorating station 6 and the final glazing station 4.

[0076] The detection sensors V are preferably, but not exclusively, cameras; alternatively, the detection sensors V are optical sensors or of a type known in the sector.

[0077] The control system can comprise, for example, but not exclusively, a PC integrated with management software; the PC can have a terminal, for example a monitor, by means of which an operator can display and/or modify the parameters of interest or other operating parameters of the glazing island 1 and of the base application station 8, decorating station 6 and/or final glazing station 4.

[0078] Advantageously, the control system is configured to transform the parameters of interest communicated by the detection sensors V into path information corresponding to the correct sequence of branches Li and common branches Lc that each slab-shaped semi-finished product 2 must pass along in order to produce on said slab-shaped semi-finished product 2, depending on the batch it belongs to.

[0079] Moreover, the control system is adapted to coordinate the movement of the slab-shaped semi-finished products 2 by activating the base applicators 9 and/or the decorating devices 7 and/or the dispensing devices 5.

[0080] Finally, the control system is adapted to modify the path information in real time, following the command of an operator. This command can be sent by the operator, for example, via one or more of the terminals of the control system: in other words, if an operator sends a command to produce a finished slab-shaped product 2f having a base, decoration and/or covering substance combination differing from those currently in production, the control system is configured to coordinate the movement of one or more slab-shaped semi-finished products 2 according to a new path given by a different combination of branches Li and common branches Lc, corresponding to the command sent by the operator.

[0081] In a highly advantageous manner, by combining the final glazing station 4, decorating station 6 and base glazing station 8 and using, respectively, one or more dispensing devices 5, decorating devices 7 and base applicators 9, it is possible to obtain, within a production plant 10 comprising the glazing island 1, a large variety of batches having different surface finishes; thanks to the possibility of passage along the distinct and independent branches Li and the common branches Lc of the conveyor line L and thanks to the regulating and coordinating action of the control system communicating with the detection sensors V, the glazing island 1 completes the aforesaid large variety of batches in an efficient, flexible manner, avoiding wastes of time that translate into economic losses.

[0082] The subject matter of the present invention, therefore, also relates to a production plant 10 comprising the glazing island 1 described in the previous paragraphs (figures 2 and 3).

[0083] The production plant 10, in fact, comprises the conveyor line L identifying the conveyance direction X, said conveyor line comprising the conveyor surface 3 moving in the conveyance direction X.

[0084] A plurality of production islands are located along the conveyor line L, the production islands corresponding to a plurality of processing steps starting from one or more raw materials, until obtaining the finished slab-shaped products 2f.

[0085] Moreover, the conveyor line L comprises two or more distinct and independent branches Li, which represent alternative paths that a slab-shaped semi-finished product 2 follows within the production plant 10 in order to be transformed into the desired finished slab-shaped product 2f. The production plant 10 is for example, but not exclusively, a ceramics manufacturing plant 10.

[0086] The production plant 10 according to the present invention, schematically represented in figure 4, comprises a plurality of islands, in particular:

• a forming island 11, comprising one or more forming machines 12, wherein each forming machine 12 is located on a branch Li of the conveyor line L and wherein each forming machine 12 is adapted to form a slab-shaped semi-finished product 2 from raw materials introduced into the forming machines 12 by means of feed devices. Within the forming island 11, the forming machines 12 are configured to compact, press and/or extrude the raw materials. The raw materials preferably, but not exclusively, comprise ceramic compounds. Each forming machine 12 is distinct and independent from the other forming machines 12 and is located on a branch Li of the conveyor line. The forming machines are of the type known to the sector.
• the glazing island 1, located downstream of the forming island 11 relative to the conveyance direction X, is adapted to receive as input the slab-shaped semi-finished products 2 output from the forming island 11. The glazing island 1 is of the type described in the previous paragraphs and comprises one or more of the base glazing station 8, the decorating station 6 and the final glazing station 4; preferably, but not exclusively, the glazing island comprises at least the final glazing station 4. When output from the glazing island 1, the slab-shaped semi-finished product 2 will have a surface finish having one or more of a base, decoration and covering substance, dispensed by the respective stations (8,6,4), according to the procedures described previously.
• a firing island 13, situated downstream of the glazing island 1 relative to the conveyance direction X: the firing island 13 preferably, but not exclusively, comprises a kiln of the type known to the sector and is adapted to complete the transformation of the slab-shaped semi-finished products 2 into the finished slab-shaped products 2f, by consolidating the base, the decoration and/or the covering substance dispensed by the glazing island 1. In particular, the firing island 13, in the case of ceramic slab-shaped semi-finished products 2, sinters the slab-shaped semi-finished product obtained as output from the forming island 11, thus bringing about the consolidation of the raw materials used.

[0087] Furthermore, the production plant 10 can comprise a cutting island 14 downstream of the forming island 11; the cutting island 14 comprises one or more cutting devices 15 and each cutting device 15 is located on a branch Li of the conveyor line L. Each cutting device 15 is configured to receive as input the slab-shaped semi-finished product 2 formed by the forming island 11 and to perform at least one cutting operation on that slab-shaped semi-finished product 2. For example, but not exclusively, the cutting operation can regard edge portions: such a cutting operation is called trimming. Various cutting devices 15 known to the sector can be used within the cutting island 14.

[0088] Moreover, the production plant 10 can also comprise a drying island 16 downstream of the forming island 11 and, preferably, downstream of the cutting island 14 relative to the conveyance direction X; the drying island 16, comprising one or more drying units 16u, is adapted to dehumidify the slab-shaped semi-finished product 2 before the latter is conveyed towards the glazing island 1. In fact, the base and/or the decoration and/or the covering substance adhere better to the upper surface S of the slab-shaped semi-finished product 2 if that slab-shaped semi-finished product 2 has a reduced percentage by weight of water.

[0089] In a further embodiment, the production plant 10 also comprises an island for cutting sub-multiples 17 downstream of the glazing island 1 relative to the conveyance direction X; the island 17 for cutting sub-multiples comprises one or more cutting devices 15. The cutting devices 15 comprised in the island 17 for cutting sub-multiples can exploit analogue technology or different technologies from the cutting devices 15 comprised in the cutting island 14.

[0090] Each cutting device 15 is located along a branch Li of the conveyor line L. Each cutting device 15 is adapted to receive as input the slab-shaped semi-finished product 2 from the glazing island 1 and to perform at least one cutting operation on that slab-shaped semi-finished product 2. The island 17 for cutting sub-multiples is configured for example, but not exclusively, to obtain finished slab-shaped products 2f of a smaller size from slab-shaped semi-finished products 2 of a larger size output from the glazing island 1. The cutting devices 15 can be of various types known to the sector.

[0091] The production plant 10 according to the present invention can further comprise one or more storage islands 18, located along the conveyor line L; each storage island 18 is adapted to store a predetermined number of slab-shaped semi-finished products 2. The maximum number of slab-shaped semi-finished products 2 that may be stored within each storage island 18 is also defined as maximum capacity.

[0092] Each storage island 18 is provided with a handling means adapted to pick up the slab-shaped semi-finished products 2 moved along the conveyor line L in order to bring about the storage thereof and handling means adapted to pick up the stored slab-shaped semi-finished products 2 in order to place them back on the conveyor line L and, preferably, on the respective branch Li.

[0093] The storage islands 18 can be conveniently located in one or more positions along the conveyor line L.

[0094] Each production island (11,14,16,1,17,13) within the production plant 10, in fact, has a respective operating time, corresponding to the time necessary for that island to complete the operation for which it is configured. A storage island 18 can be for example, but not exclusively, located downstream of the cutting island 15 or of the drying island 16 and upstream of the glazing island 1.

[0095] In fact, the cutting island 15 and the drying island 16 have considerably shorter operating times than the glazing island 1. Moreover, the glazing island 1 has an operating time that varies according to the glazing performed.

[0096] The storage island 18 advantageously makes it possible not to interrupt the operations performed by the cutting island 15 and/or drying island 16 while waiting for the glazing island 1 to complete particularly complex glazing operations: advantageously, the storage island 18 allows for the creation of a collection reservoir, which the glazing island 1 can draw from as needed.

[0097] When the maximum capacity of the storage islands 18 is appropriately pre-set and they are appropriately located along the conveyor line L, no island within the production plant 10 will be left inoperative for long periods. Advantageously, in other words, the wastes deriving from the different operating times of the production islands (11,14,16,1,17,13) will be limited.

[0098] Similarly to what was affirmed for the glazing island 1, the production islands (11,14,16,1,17,13) are also connected by common branches Lc resulting from the convergence of branches Li of the production islands upstream, said common branches Lc being divided in the production islands downstream, considering the conveyance direction X.

[0099] The production plant 10 comprises a general control system adapted to monitor and regulate the production of different batches of finished slab-shaped products 2f.

[0100] In detail, the general control system is connected to an actuator means, adapted to bring about the movement of the slab-shaped semi-finished products 2 through the production islands (11,14,16,1,17,18,13). Thanks to the general control system, each slab-shaped semi-finished product 2 is moved along the correct branches Li of the conveyor line L.

[0101] The general control system receives as input path information relating to the correct sequence of branches Li that each slab-shaped semi-finished product 2 must pass along in order to be transformed into the desired finished slab-shaped product 2f starting from the raw materials introduced into the forming island 11.

[0102] Moreover, the general control system is adapted to coordinate the movement of the slab-shaped semi-finished products 2 with a distinct and independent activation of the production islands (11,14,16,1,17,13,18).

[0103] Moreover, the general control system is adapted to send to the handling means an operating command to place the slab-shaped semi-finished products 2 in the storage islands 18 or an operating command to pick up the slab-shaped semi-finished products 2 from the storage islands 18 according to production requirements and the operating times of each island.

[0104] Furthermore, the general control system is adapted to modify the path information in real time, following the command of an operator, similarly to what was described for the glazing island 1: if an operator sends a command to produce a finished slab-shaped product 2f differing from those currently in production, the general control system is configured to coordinate the movement of one or more slab-shaped semi-finished products 2 according to a new path corresponding to the command sent by the operator.

[0105] According to the batch or batches of finished slab-shaped products 2f it is intended to produce, the general control system is configured to send operating signals to each production island (11,14,16,1,17,13,18) within the production plant 10; every production island (11,14,16,1,17,13,18) is in fact connected to a local control system, configured to manage the operations performed by said production island (11,14,16,1,17,13,18).

[0106] In detail, each local control system comprises one or more detection sensors V, adapted to detect parameters of interest relating to each semi-finished product 2; in other words, the detection sensors V are configured to detect at least one parameter of interest, such as shape, size, surface characteristics, or other parameters characterising the slab-shaped semi-finished product 2 and to send those parameters to the local control system; the local control system, on the basis of the parameters received from the detection sensors V, sends operating commands to actuators adapted to move the slab-shaped semi-finished product 2 along the correct branch Li of the conveyor line L.

[0107] Preferably, the detection sensors V are located along the common branches Lc, so as to detect the parameters of interest and so as to bring about the movement of each slab-shaped semi-finished product 2 along the correct branch Li.

[0108] The detection sensors V are preferably, but not exclusively, cameras; alternatively, the detection sensors V are optical sensors or of the type known in the sector.

[0109] Each local control system can comprise for example, but not exclusively, a PC integrated with management software; the PC can have a terminal, for example a monitor, by means of which an operator can display and/or modify the parameters of interest or other operating parameters of each production island (11,14,16,1,17,13,18).

[0110] Advantageously, each local control system is configured to transform the parameters of interest communicated by the detection sensors V into path information corresponding to the correct sequence of branches Li and common branches Lc that each slab-shaped semi-finished product 2 must pass along in order to produce on said slab-shaped semi-finished product 2, depending on the batch it belongs to.

[0111] Once instructed by the general control system, every local control system can operate autonomously from the other local control systems and autonomously from the general control system.

[0112] Advantageously, even in the event of a malfunction or maintenance of the general control system, the local control systems continue to operate.

[0113] Advantageously, in the event of a malfunction or maintenance of a local control system, the other local control systems can continue to operate once instructed by the general control system.

[0114] Similarly to what was affirmed for the general control system and for the glazing island 1, each local control system is configured to modify the path information in real time, following the command of an operator. This command can be sent by the operator, for example, via the terminals of the local control systems.

[0115] Moreover, the general control system allows each slab-shaped semi-finished product 2 to be traced from the forming thereof in the forming island 11, to its exit from the kiln 13 and to any subsequent packaging and storage stations: thanks to said tracing, every slab-shaped semi-finished product 2 undergoes the correct succession of steps for obtaining the finished slab-shaped product 2f. Moreover, thanks to the tracing it is possible to detect, at the exit of every island, the presence of any operating errors and it is possible to intervene promptly, thus limiting the waste of raw materials and energy.

[0116] For the purpose of carrying out the aforesaid tracing, the production plant 10 advantageously comprises a printing unit P adapted to print an identification code on each slab-shaped semi-finished product. The printing unit P can be advantageously located in various points along the conveyor line L: preferably, but not exclusively, the printing unit P is located between the forming island 11 and the drying island 16.

[0117] The identification code, preferably a bar code, allows the specific slab-shaped semi-finished product 2 to be identified and is attributed to each slab-shaped semi-finished product 2 on the basis of the final product 2f it is intended to obtain.

[0118] The production plant 10 further comprises at least one reading device R for reading said identification code; the reading device R is for example a detection sensor and preferably an optical sensor.

[0119] Reading devices R can be located in various positions along the conveyor line: preferably, a first reading device R is located at the entry to each production island (11,14,16,1,17,13,18) and a second reading device R is located at the exit of each production island (11,14,16,1,17,13,18).

[0120] The reading device R is configured to detect the identification code printed on the slab-shaped semi-finished product 2 by the printing unit P; furthermore, the reading device R can be configured to communicate said identification code to the local and/or general control system. The identification code communicated by the reading devices R can be used by the local and/or general control system for various operations: for example, the reading of the identification code makes it possible to trace the progress of each slab-shaped product 2 along the conveyor line L and through the production islands (11,14,16,1,17,13,18), verify that each slab-shaped product 2 follows the correct path defined by the correct sequence of branches Li and common branches Lc, detect the presence of errors in the path followed by the slab-shaped semi-finished products 2 and/or detect any slowdowns in the production process. Further operations can be easily foreseen by the person skilled in the art based on the information provided.

[0121] Advantageously, thanks to the printing unit P and the reading devices R, it is possible to follow each slab-shaped semi-finished product 2 through all the production steps corresponding to the production islands (11,14,16,1,17,13,18).

[0122] Advantageously, it is further possible to detect errors in the production of the finished products 2f and malfunctions of the production islands (11,14,16,1,17,13,18).

[0123] In one embodiment, the reading devices R are integrated with the detection sensors V described above.

[0124] Figure 3 illustrates the preferred embodiment of the production plant 10 according to the present invention.

[0125] In particular, the production plant 10 according to the present invention comprises a forming island 11 comprising three forming machines 12; the slab-shaped semi-finished products 2 output from the forming machines 12 are then conveyed in the conveyance direction X along the common branch Lc towards the drying island 16: the drying island 16 comprises two drying units 16u. A storage island 18 is preferably located downstream of the drying island 16; it is adapted to store the dehumidified slab-shaped semi-finished products 2 before the conveyance thereof along the respective branches Li within the glazing island 1.

[0126] The glazing island 1 comprises, preferably and similarly to what was described previously, two operative base applicators 9 and a base applicator 9 activated only in the event of particular production needs, three operative decorating devices 7 and three decorating devices 7 activated for the aforesaid particular production needs; moreover, the glazing island 1 comprises two operative dispensing devices 5 for the base and two further dispensing devices 5, activated in the event of particular production needs.

[0127] On exiting from the glazing island 1, the slab-shaped semi-finished products 2 are conveyed through the island 17 for cutting sub-multiples, in which a plurality of slab-shaped products 2 of a smaller size are obtained from a slab-shaped product 2 of a larger size.

[0128] Finally, the slab-shaped semi-finished products 2 obtained can be conveyed towards the firing island 13, at the exit of which the finished slab-shaped products 2f are obtained.

[0129] Two further storage islands are also preferably included: one is located between the base decorating station 8 and the decorating station 6, and the other is located between the decorating station 6 and the final glazing station 4.

[0130] Advantageously, the production plant 10 according to the present invention, thanks to the plurality of branches Li and common branches Lc which connect the production islands (11,14,16,1,17,13,18) and the general control system described above, allows a greater flexibility and versatility of production to be achieved compared to production plants as per the prior art: the production plant 10 can be thus be used to simultaneously produce a wide variety of batches of finished slab-shaped products 2f, batches that are distinguished by their aesthetic characteristics, surface mechanical and structural properties, and/or sizes. Advantageously, the production plant 10 according to the present invention allows the aforesaid wide variety of batches to be obtained in a rapid and efficient manner. In fact, thanks to the presence of the plurality of branches Li and the storage islands 18, it is possible to overcome the production limits deriving from the different operating times of the production islands (11,14,16,1,17,13).

[0131] Moreover, thanks to the presence of the different branches Li and the possible activation of further machines and devices in the event of particular production needs within each production island (11,14,16,1,17,13), it is advantageously possible to modify, as needed, the path followed by the slab-shaped semi-finished products 2, thereby isolating local malfunctions and enabling routine or extraordinary maintenance operations to be performed without having to totally interrupt the conveyor line L.

[0132] Advantageously, the production plant 10 according to the present invention makes it possible to reduce wastes in terms of raw materials, time and the energy consumed.

[0133] Advantageously, in conclusion, the production plant 10 makes it possible to overcome the production rigidity characterising production plants as per the prior art.

Claims

1. A glazing island (1) for slab-shaped semi-finished products (2) having an upper surface (S), comprising:

- a conveyor line (L), comprising a conveyor surface (3) that is movable along a conveyance direction (X), wherein the conveyor line (L) comprises two distinct branches (Li);

- a final glazing station (4), adapted to deposit a covering substance on the upper surface (S) of the slab-shaped semi-finished products (2) moved by the conveyor surface (3) along the conveyor line (L),

characterised in that the final glazing station (4) comprises at least two dispensing devices (5), distinct and independent from each other, wherein each dispensing device (5) is located on a branch (Li) of the conveyor line (L) and is adapted to deposit a covering substance on the upper surface (S) of the slab-shaped semi-finished products (2) moved by the conveyor surface (3) along that branch (Li) of the conveyor line (L).

2. The glazing island according to claim 1, comprising a decorating station (6), situated upstream of the final glazing station (4) relative to the conveyance direction (X), and adapted to produce a decoration on the slab-shaped semi-finished products (2) moved by the conveyor surface (3) along the conveyor line (L).

3. The glazing island according to claim 2, wherein the decorating station (6) comprises one or more decorating devices (7), distinct and independent from each other, wherein each decorating device (7) is located on a branch (Li) of the conveyor line (L) and is adapted to deposit a decoration on the slab-shaped semi-finished products (2) moved by the conveyor surface (3) along that branch (Li) of the conveyor line (L).

4. The glazing island according to claim 3, wherein the decorating devices (7) are ink-jet printers.

5. The glazing island according to any one of the preceding claims, comprising a base glazing station (8), situated upstream of the final glazing station (4) relative to the conveyance direction (X), and adapted to deposit a base on the slab-shaped products (2) moved by the conveyor surface (3) along the conveyor line (L), and wherein
the base glazing station (8) comprises one or more base applicators (9), distinct and independent from each other, wherein each base applicator (9) is located on a branch (Li) of the conveyor line (L) and is adapted to apply a base on the slab-shaped semi-finished products (2) moved by the conveyor surface (3) along that branch (Li) of the conveyor line (L).

6. The glazing island according to any one of the preceding claims, comprising a control system connected to an actuator means, wherein the control system is adapted to send the actuator means an operating command to move the slab-shaped semi-finished products (2) along the branches (Li) of the conveyor line (L).

7. A plant (10) for the production of finished slab-shaped products (2f), comprising:

- a conveyor line (L), comprising a conveyor surface (3) that is movable along a conveyance direction (X), wherein the conveyor line (L) comprises a plurality of alternative branches (Li);

- a forming island (11), comprising one or more forming machines (12), wherein each forming machine (12) is located on a branch (Li) of the conveyor line (L) and wherein each forming machine (12) is adapted to form a slab-shaped semi-finished product (2) from raw materials introduced into the forming machines (12) by means of feed devices;

- a glazing island (1), located downstream of the forming island (11) relative to the conveyance direction (X), and adapted to receive as input the slab-shaped semi-finished products (2) output from the forming island (11);

- a firing island (13), comprising a kiln situated downstream of the glazing island (1) relative to the conveyance direction (X) and adapted to transform the slab-shaped semi-finished products (2) into finished slab-shaped products (2f),

characterised in that the glazing island (1) is a glazing island according to one of claims 1-6.

8. The plant according to claim 7, wherein in the forming island (11) the forming machines (12) are configured to compact, press and/or extrude the raw materials, wherein the raw materials comprise ceramic compounds.

9. The plant according to one of claims 7 and 8, comprising a cutting island (14) downstream of the forming island (11) according to the conveyance direction (X), the cutting island (14) comprising one or more cutting devices (15), wherein each cutting device (15) is located on a branch (Li) of the conveyor line (L) and wherein each cutting device (15) is adapted to receive as input the slab-shaped semi-finished product (2) formed by the forming island (11) and to perform at least one cutting operation on that slab-shaped semi-finished product (2).

10. The plant according to one of the preceding claims, comprising a drying island (16) downstream of the forming island (11) according to the conveyance direction (X), the drying island (16) being adapted to dehumidify, at least partially, the slab-shaped semi-finished products (2) output from the forming island (11).

11. The plant according to one of the preceding claims, comprising an island (17) for cutting sub-multiples downstream of the glazing island (1) relative to the conveyance direction (X), the island (17) for cutting sub-multiples comprising one or more cutting devices (15), wherein each cutting device (15) is located along a branch (Li) of the conveyor line (L) and wherein each cutting device (15) is adapted to receive as input the slab-shaped semi-finished product (2) from the glazing island (1) and to perform at least one cutting operation on that slab-shaped semi-finished product (2).

12. The plant according to one of the preceding claims, comprising at least one storage island (18) comprising a handling means, the storage island (18) being adapted to:

- store the slab-shaped semi-finished products (2) picked up from the conveyor line (L) via the handling means; and

- transfer, via the handling means, the slab-shaped semi-finished products (2) stored on the respective branch (Li) of the conveyor line (L).

13. The plant according to one of the preceding claims, comprising a general control system connected to an actuator means, wherein the general control system is adapted to send the actuator means an operating command to move the slab-shaped semi-finished products (2) along the branches (Li) of the conveyor line (L) and to detect and signal the presence of production errors on the outfeed side of each production island (11,14,16,1,17,13,18) of the production plant (10).

14. The plant according to claim 13, wherein the general control system is configured to send local operating commands to a plurality of local control systems, each local control system being connected to a respective production island (11,14,16,1,17,13,18) comprised in the production plant (10), the local control systems operating independently of the general control system after having received said local operating commands.

15. The plant according to one of claims 13 and 14, comprising a printing unit (P) configured to apply an identification code on each slab-shaped semi-finished product (2), and at least one reading device (R) adapted to detect said identification code and to communicate said identification code to the local and/or general control system.

Drawing