Technical Field

The invention relates to a cutting machine and the working method of this cutting machine.

In particular, the present invention discloses a cutting machine and a related method that performs sponge cutting operations with five pulleys and vibration, so that it can be used in areas lower in height.

Prior Art

Sponge is a porous material with good water absorption. Sponges commonly used by people are made of wood cellulose fiber or foamed plastic polymer.

Sponges are used in many different areas, from cleaning to furniture. Mainly, its main material is low density polyether but there are three types of synthetic sponge made of other materials; non-absorbent sponge, polyvinyl alcohol (super absorbent material, no obvious pores) and polyester.

Sponges, which are mostly used in the furniture industry, beds and sofas, etc., need to be cut in different geometries depending on the area of use and the models they will be used in. After the sponge is obtained, it is cut and shaped with sponge cutting machines. Polyether sponges, especially used in furniture and beds production, are cut with sponge cutting machines moving on four movement pulleys.

In these machines, knife movement is provided through a mechanism guided by wire or steel wire. During this cutting, sponge comes to the knife along with the band in the horizontal plane and is cut by the up and down movement of the knife. However, in existing sponge cutting machines, the cutting unit moves up and down approximately 1400 mm. As a result, the working height of the machine reaches 4.5-5 meters and this becomes a big problem for businesses with space constraints. At the same time, sponge cutting machines, which have complex structures, are produced by machine manufacturers at high costs, and machine assembly and transportation negatively affect the sales of the product.

Therefore, there was a need for compact sponge cutting machines that can be used in working areas lower in height and have a simple installation, that is, a working height of 2-3 meters. The patent document CN113427543A relates to a sponge cutting machine and cutting mechanism. The purpose of the machine in the mentioned patent document is to ensure that the cut piece is rotated as desired by adjusting the fixed cutting direction. In addition, it is to sharpen the knife, which becomes dull after a long period of use, and to ensure the cleaning of the ring, which easily creates dust during cutting. However, the solution explained here does not have an effect on the working height of the machine or does not provide a structure suitable for areas where the working height is low.

The utility model document CN201275770Y relates to a numerically controlled (CNC) specialshaped sponge cutting machine. With the mentioned utility model, a type of cutting machine that cuts especially fluffy and flexible materials is obtained. This advantage provided to the machine does not solve the problem of space limitation.

The patent document CN1 13400393A relates to a sponge cutting device used in bed processing. Here, it is aimed to solve the problem caused by the inability to cut the desired thickness, length and width in sled type band saw machines, especially used in cutting sponge beds. However, there is no change in the working height of the disclosed cutting machine.

The utility model document TR2009/00369 relates to a CNC sponge, polyurethane, aerated concrete cutting machine. In the mentioned utility model document, it is aimed to cut the endless model quickly, in exact dimensions, with very little wastage, without using any molds, through a computer program. These advantages in the resulting cutting machine are provided especially by the configurations in the CNC program. There are no special design changes in the machine body or structure.

As a result, there are studies aimed at making the cutting process smooth, waste-free and fast for all types of sponges in known sponge cutting machines that have been developed or continue to be used in the current technique. However, a solution that will enable the use of these machines in limited areas has not yet emerged, and it is understood that such a solution is a serious need, especially for businesses having small sites.

Objectives and Brief Description of the Invention

The main purpose of the present invention is to reduce the cutting height in cutting machines.

Another aim of the invention is to enable cutting operations to be carried out at more affordable costs by using fewer and simpler parts.

Another purpose of the invention is that the machine body structure is more compact, allowing ease of transportation and assembly. In order to realize the above purposes, the invention is cutting machine having a main body comprising at least two support columns and a tension wire, and further comprising; first movement pulley and fourth movement pulley, one on each of the mentioned support columns, located opposite to each other and connected to each other by means of tension wires, second movement pulley and third movement pulley, cross-positioned one on each of the mentioned support columns, and connected to each other by means of a tension wire,

- a tensioning pulley positioned between the second movement pulley and the third movement pulley and connected to them by means of a tension wire.

The cutting machine according to the invention further comprises a tensioning element which operates in connection with the tensioning pulley and provides movement in a horizontal plane to the tensioning pulley.

In the preferred embodiment of the invention, mentioned tensioning element is a piston.

In another preferred embodiment of the invention, each of mentioned support columns is provided with a mounting plate aligned parallel to each other.

The support columns, disclosed in the invention, have a height hi , and mentioned crosspositioned first movement pulley and fourth movement pulley are positioned on the mentioned mounting plates. Here, the first movement pulley on the mounting plate is located at a height h2 and the fourth movement pulley on another mounting plate is located at a height h3. The height h3 is shorter than the height h2. The height difference between the height h3 and the height h2 is being as the diameter of a pulley. The height h2 is shorter than the height hi .

The cutting machine of the invention also comprises an angle motor for angular movement of the tension wire, a servo motor which triggers the angle motors and provides position and speed control during cutting, and an eccentric unit comprising an eccentric arm for vibratory cutting and a motor which triggers the eccentric arm, built on the said mounting plates.

In another embodiment of the invention, the cutting machine comprises a press unit extending perpendicularly to the two support columns between these columns and having vertical movement up and down along the height h4, and a main motor positioned on the press unit to provide motive power to the cutting machine.

In a further embodiment of the invention, it comprises a conveyor table which carries the material to be cut towards the tension wire and supports it from below. It further comprises a bridge connecting the support columns from above and carrying the tension wire between the second movement pulley on one of the columns and the tensioning pulley.

The cutting machine of the invention also includes protection caps covering the support columns and the bridge, and is operated by a CNC device to which the commands for the cutting process are loaded.

For cutting sponge and similar materials and giving them the specified form, the method disclosed by the invention comprises the process steps of

- loading the material to be cut onto the conveyor table and moving it to the cutting area,

- fixing the material to be cut between the press unit and the conveyor table,

- by triggering the mounting plate with the main motor, moving the mounting plates up and down on the support columns along the height hi ,

- actuation of the tension wire around four movement pulleys and one tensioning pulley by means of servo motor triggering,

- keeping movement of the tension wire of the tensioning pulley at a constant tension by means of the tensioning element, performing the cutting operation of the tension wire passing between the first movement pulley and the fourth movement pulley on the mounting plate.

Besides, in the working method of the cutting machine, the tension wire makes vibratory cutting process by means of an eccentric arm. It is also possible for the tension wire to cut at an angle by means of an angle motor.

Brief Description of the Figures

In Figure 1 , the front view of the internal structure of the inventive sponge cutting machine is given.

In Figure 2, a side view of the internal structure of the inventive sponge cutting machine is given.

In Figure 3, a perspective view of the internal structure of the sponge cutting machine of the invention is given. In Figure 4, a top view of the internal structure of the sponge cutting machine of the invention is given.

In Figure 5, an assembled view of the front protection caps of the sponge cutting machine of the invention is given.

Reference Numbers

I . Sponge cutting machine

10. Main body

I I . Press unit

12. Protection caps

13. Mounting plate

14. Conveyor table

15. Servo motor

16. Support column

17. Bridge

20. Tensioning pulley

21. Tensioning element

30. First movement pulley

31. Second movement pulley

32. Third movement pulley

33. Fourth movement pulley

40. Tension wire

41 . Eccentric arm

50. Angle motor

60. Main motor hi Support column height h2 Height of the pulley on one of the columns h3 Height of the pulley on the other of the columns h4 Press unit movement height Detailed Description of the Invention

The present invention discloses a cutting machine (1 ) and a method for cutting sponge and the like using a five-pulley structure and a vibratory cutting method.

The sponge cutting machine (1 ) embodiment of the invention essentially comprises different elements with movement in different axes. Therefore, in Figure 1 , the respective axes of motion are shown in the x-, y- and z-axes.

Of these movements, especially the vertical linear movement in the y-axis, up and down, is realized at different heights or lengths by different movement structures. For this reason, the lengths hi , h2, h3, h4 are defined.

According to the preferred embodiment shown in Figure 1 , the inventive cutting machine (1 ) comprises a fixed main body (10), a conveyor table (14) moving in the z-axis, a tension wire (40) moving in the x- and y-axes, and a CNC machine to operate this system. The cutting machine (1 ) further comprises 4 movement pulleys (30, 31 , 32, 33) around which said tension wire (40) rotates and thus gains motion, and a tensioning pulley (20) which enables the tension wire (40) to perform cutting at any height. The tensioning pulley (20) is triggered by a tensioning element (21 ).

Mentioned main body (10) comprises two fixed support columns (16), a fixed bridge (17) connecting these support columns (16) from above, a press unit (11 ) extending perpendicularly to these columns (16) between the support columns (16), a main motor (60) positioned on this press unit (1 1 ) and mounting plates (13) positioned one on each of mentioned support columns (16). The first movement pulley (30) is positioned on the mounting plate (13) on the right support column (16), the second movement pulley (31 ) is positioned on the upper part of the right support column (16), the third movement pulley (32) is positioned on the lower part of the left support column (16), and the fourth movement pulley (33) is positioned on the mounting plate (13) on the left support column (16).

The aforementioned main motor (60) provides movement to the tension wire (40) and thus to the movement pulleys (30, 31 , 32, 33). This movement of the tension wire (40) extends from the bottom of the first movement pulley (30) upwards to the second movement pulley (31 ), and it continues upwards from the top of the second movement pulley (31 ) to the left to the tensioning pulley (20). It moves from the upper part of the tensioning pulley (20) to the third movement pulley (32) located at the lowest part of the support column (16), and from the lower part of the third movement pulley (32) to the upper part of the fourth movement pulley (33), and from there to the upper part of the upper part of the fourth movement pulley (33) to the first movement pulley (30).

The first movement pulley (30) and the fourth movement pulley (33) are positioned opposite each other on the mounting plates (13). The aforementioned support columns (16) have a height of hi , and in this arrangement;

- the first movement pulley (30) on the right side of the mounting plates (13) is located at height h2, and the fourth movement pulley (33) on the other side of the mounting plates (13) is located at height h3, the height h3 is shorter than the height h2 and the difference is being as the diameter of a pulley, the height h2 is shorter than the height hi .

The bridge (17) mentioned above also encircles the tension wire (40) between the supporting columns (16).

The press unit (11 ) is movable vertically in the y-axis, up and down along the height h4, and the main motor (60) providing motive power to the cutting machine (1 ) is preferably located on mentioned press unit (1 1 ). The press unit (1 1 ) extends along the x-axis when viewed from the front in Figure 1 . When viewed from the side, as shown in Figure 2, it also extends in the z-axis. While the press unit (11 ) is stationary in the x- and z-axes, it has linear motion in the y-axis. This movement allows it to compress the material from the upper surface during sponge cutting and provides more precise cutting results. A top perspective view of the bridge (17) is shown in Figure 3 and a top view is shown in Figure 4.

The support columns (16) and bridge (17) explained above are covered by the protection caps (12) shown in Figure 5, for both protecting the machine and providing visual aesthetics. Protection caps (12) protect all parts of the internal structure of the sponge cutting machine (1 ) from dust and dirt. At the same time, it is also important in terms of occupational safety.

The cutting process can be carried out by means of the known tension wire (40). However, unlike the known state of the art, this tension wire (40) moves on 5 pulleys. While 4 of these pulleys are movement pulleys (30, 31 , 32, 33), 1 of them is a tensioning pulley (20). The inventive cutting machine (1 ) briefly comprises first movement pulley (30) and fourth movement pulley (33), which are mutually positioned on each of the mentioned carrier columns (16) and connected to each other by means of a tension wire (40), second movement pulley (31 ) and third movement pulley (32), which are crosspositioned on each of the mentioned supporting columns (16),

- a tensioning pulley (20) positioned between the second movement pulley (31 ) and the third movement pulley (32) and connected therewith by means of a tension wire (40).

The first movement pulley (30) and the fourth movement pulley (33) are mounted on mounting plates (13), which are essentially positioned on the support columns (16). The first movement pulley (30) and the fourth movement pulley (33) are connected by means of a tension wire (40) to the second movement pulley (31 ) mounted at the upper right end and the third movement pulley (32) mounted at the lower diagonal end of the same support column (16). The second movement pulley (31 ), mounted on the upper end of the support column (16), is connected to the tensioning pulley (20), mounted on the upper end of the other support column (16), preferably through the bridge (17) by means of the tension wire (40). The tensioning pulley (20) is also connected by means of the tension wire (40) to the third movement pulley (32) mounted at the lower end of the same support column (16). Finally, the third movement pulley (32) is also connected to the fourth movement pulley (33) mounted on the mounting plate (13) of the same support column (16). Therefore, the tension wire (40) moves in the x- and y-axes between the two support columns (16).

A mounting plate (13) is positioned on each column (16) of the support and can move linearly up and down in the y-axis. Each mentioned mounting plate (13) comprises an angle motor (50) mounted thereon and a servo motor (15) connected to the angle motor (50).

Only one of the support columns (16) is provided with an eccentric unit. The eccentric unit comprises at least one eccentric arm (41 ) for vibratory cutting of the tension wire (40) in the cutting process and for adjusting the cutting speed, and at least one trigger element for triggering the eccentric arm (41 ). The trigger is preferably a motor, which is not shown in the figures as it is positioned under the mounting plate (13).

The tension wire (40), the angle motor (50) and the servo motor (15) working in conjunction with it form the wire-knife system. With the additional third movement pulley (32), the length of the tension wire (40) is extended, while the main body (10) of the cutting machine (1 ) performs the same cutting function, although its height remains constant.

The tensioning pulley (20) mounted at the upper end of one of the support columns (16) is connected with a tensioning element (21 ) and is driven by the tensioning element (21 ). This tensioning element (21 ) ensures that the tension wire (40) remains at the appropriate tension during the sponge cutting process, so that at any time the wire (40) is operated at the correct tension. The tensioning element (21 ) referred to herein is preferably a piston, alternatively springs and similar compression elements may be used.

As seen in Figure 1 , the conveyor table (14) is positioned in the part of the main body (10) close to the floor. The conveyor table (14) is the mechanism where the sponge material is loaded. At the same time, the conveyor table (14) moves along the z-axis perpendicular to the cutting process and can rotate clockwise and counterclockwise around itself in the x-axis.

In the preferred embodiment of the invention, the sponge cutting machine (1 ) performs cutting operations with computerized numerical control (CNC).

In the working principle of the sponge cutting machine (1 ), the tension wire (40) starts to work synchronously with the movement of the main motor (60). After the sponge material is placed on the conveyor table (14), the conveyor table (14) moves towards the area to be cut. The tension wire (40) is guided by the operator to the cutting point on the sponge by means of movement pulleys (30, 31 , 32, 33). The appropriate dimensions for cutting are uploaded to the control computer by the operator. When the cutting starts, the machine performs the cutting process with 3 axes.

For cutting sponge and similar materials and giving them a specified form, the cutting machine (1 ) operation method comprises the following steps of

- loading the material to be cut onto the conveyor table (14) and moving it to the cutting area,

- fixing the material to be cut between the press unit (1 1 ) and the conveyor table (14),

- by triggering the mounting plate (13) with the main motor (60), moving the mounting plates (13) up and down on the support columns (16) along the height hi ,

- actuation of the tension wire (40) around four movement pulleys (31 , 32, 33, 34) and one tensioning pulley (20) by means of servo motor (15) triggering,

- keeping movement of the tension wire (40) of the tensioning pulley (20) at a constant tension by means of the tensioning element (21),

- performing the cutting operation of the tension wire (40) passing between the first movement pulley (30) and the fourth movement pulley (33).

In the method, preferably, the tension wire (40) can be made to perform vibratory cutting by means of the eccentric arm (41 ). It is possible, alternatively, the tension wire (40) may be perform to cut at an angle by means of the angle motor (50).