Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
~. 2161815
APPARATUS FOR CLEANING A WELDED JOINT
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates to a device for cleaning excess material from welded joints and
5 more particularly to an automated device for cleaning excessive polymeric material from the
corner joints of extruded window and door assemblies and the like.
DISCUSSION OF THE RELATED ART
Windows, door assemblies, and the like have been manufactured for some time wherein
the window and door frames/jams are assembled from extruded polymeric material, typically
10 polyvinyl chloride (PVC). The extruded profiles are welded together by partially melting the
ends of the components to be joined and while the polymeric material is molten, mating the ends
to be joined. The joint is static until the molten polymeric material solidifies, producing a
substantially strong joint.
A disadvantage associated with manufacturing windows, doors, and other assemblies
15 using this technique is that the welded joint between the extruded polymeric components
produces a bead or ridge which extends from the product as a result of the compression of the
components being joined. Because the material is partially molten, the material flows outwardly
in a direction generally perpendicular to the compressive force. This bead is considered to be
unattractive and undesirable and must be removed from the product to provide a finished surface.
In the past, this bead was removed by hand, however, this resulted in increased
manpower, caused physical injury to some workers, and because of the complex extrusion
shapes, the bead was often difficult to access and remove. This resulted in increased costs
associated with increased manpower and a low production rate.
In an effort to increase production and reduce the need for manpower, complex devices
25 were constructed which carried one or more routers or dremmels having a rotating cutter which,
with the aid of a robotic arm, trimmed the bead from the extruded product. However, as a
result of the rotating, relatively small cutter head, the polymeric bead was not fully removed
from the product, and often remained as a distorted string or strip h~nging from the product.
These "curlicue" pieces of material also needed to be removed and trimmed from the work piece0 by hand to produce a satisfactory and aesthetically pleasing product.
SUMMARY OF THE INVENTION
In its broadest form, the invention provides a device for mechanically trimming and
removing excess material from a work piece by automatically locating and fixing the work piece
2 1 6 1 8 1 5
-
in position on the device, and then sequentially trimming excess material from the surfaces of the
work piece either sequentially or generally simlllt~nPously.
In one form, the appdld~us includes a base frame having a locating assembly disposed on
an upper surface thereof for positioning the welded joint of the work piece at a predetermined
5 location on the device. A first cutter assembly is provided, which engages an interior surface of
the work piece and includes linearly achl~tecl knives which trim the excess material from the
inside surface of the joint. Substantially simlllt~n~ously with the actuation of the first cutter
assembly, is a second cutter assembly disposed on a side of the locating assembly opposite that
cont~ining the first cutter assembly and configured to move between a first and second position
10 tangent to the work piece for trimming excess material from at least a portion of the exterior
surface of the joint. Subsequent to the actuation of the second cutter, a third cutter assembly is
provided which is configured to move between a first and second position, generally perpendic-
ular to the work piece, for removing excess material from the lateral surfaces of the joint.
More specifically, the locating assembly includes a pair of stops or locating blocks, each
15 spaced from the other to define a gap, and configured to engage the work piece to specifically
position the welded joint of the work piece on the upper surface of the base frame. A first
clamp assembly is slidably disposed on the work surface and engages an interior side of the work
piece opposite that eng~ging the locating blocks. The first clamp assembly forces the work piece
up against the locating blocks and retains it in position until the cycle is complete. Concurrent
20 with the actuation of the first clamp assembly is a second clamp assembly located above the work
piece, which forces the work piece dowllwdfdly against the upper surface of the base frame.
The first cutter assembly includes a pair of knives mounted on the first clamp assembly and
configured to engage the inside surface of the work piece and conform substantially thereto such
that upon sequential actuation of the knives, substantially all of the excess material about the
25 joint is severed and completely removed from the work piece. The second cutter assembly
includes a cutter head having a profile substantially conforming to the exterior surface of the
work piece. The cutter head is mounted to an electric motor or other drive assembly mounted
on a carriage adapted to slide between the first and second positions controlled by an actuator
interconn~cting the carriage to the base frame. The third cutter assembly includes a pair of scarf
30 knives spaced a predetermined distance from each other and mounted to a frame configured for
linear actuation between a first retracted position and a second extended and ~ g position
by an actuator.
2161815
In another form of the invention, the first cutter assembly mounted in the first clamp
assembly includes at least one and preferably two knives configured to engage the inside surfaced
of the work piece and translate along a parallel path controlled by a channel or raceway to trim
the interior surface of the work piece. Each knife is activated by an actuator having a first end
5 fixed within the first clamp assembly and the opposite end coupled to a joint interconnecting two
links. A first link has one end pivotally coupled to and fixed to the first clamp assembly and the
opposite end pivotally coupled to the free end of the actuator. A second link has one end
pivotally coupled to the sliding knife and the opposite end pivotally coupled to the end of the
actuator and the first link. Operation of the actuator forces the links to straighten and lie
10 substantially in line with the knife causing the knife to slide in a first direction. Retraction of the
actuator causes the links to bend at the coupling, shortening the distance between the fixed part
of the first link and the end of the link coupled to the knife, causing the knife to slide in the
opposite direction.
In yet another form of the invention, the first clamping assembly is provided with a
15 position locking mechanism for holding the first clamping assembly in place while the work
piece is trimmed. In one embodiment, one or more locking pins more upward from the cabinet
into the first clamping assembly to hold it in place with respect to the cabinet during the
g cycle.
In yet another form of the invention, a router assembly may be configured with the
20 foregoing components to trim areas inaccessible to the knife or other cutters. In one
embodiment, a router is disposed beneath the work piece and configured to move upwards such
that a router blade trims an interior corner or recess of the work piece.
The invention described herein provides the advantages of more efficient and effective
removal of excess material from all sides of the joint on a work product, resulting in reduced
25 cost, increased productivity, and reduced operator injury. What used to take several minutes to
trim m~ml~lly, causing operator strain and injury, can now be trimmed autom~tir~lly in a matter
of seconds using this invention.
BRIEF DESCR~ON OF THE DRAWING FIGIJRES
A better underst~n(ling of the invention and the advantages provided thereby may be
30 obtained by r~fe~ ce to the specification and the attached drawing figures, wherein:
Fig. 1 is a perspective view of one embodiment of the invention;
Fig. 2 is a perspective plan view of the invention;
2161~5
Fig. 3 is a fragmentary, perspective plan view of the locating assembly and a portion of a
first cutter assembly used to trim the welded bead from the interior of the work piece;
Fig. 3A is a fragmentary, sectional view of the hold-down assembly taken along plane
IIIA-IIIA of Fig. 3;
Fig. 4 is a schematic illustration of a first cutter assembly as it relates to the work piece;
Fig. 5 is a fragmentary, perspective plan view of the second and third cutter assemblies
of the invention;
Fig. 6 is a fragmentary, sectional view of the second and third cutter assemblies taken
along plane VI-VI of Fig. 5 with the router in a lower position;
Fig. 7 is a fragmentary, sectional view of the third cutter assembly;
Fig. 8 is a perspective view of an alternate embodiment of the invention;
Fig. 9 is a plan view of the alternate embodiment of the invention shown in Fig. 8;
Fig. 10 is a front elevational view of the alternate embodiment shown in Fig. 9;Fig. 11 is a side elevational view of the alternate embodiment shown in Fig. 9;
Fig. 12 is a plan view of a first cutter assembly of the alternate embodiment;
Fig. 13 is a fragmentary view of the first cutter assembly looking in the direction of
arrows XII-XII shown in Fig. 12;
Fig. 14 is a fragmentary plan view of a second cutter assembly of the alternate
embodiment of the invention;
Fig. 15 is a fragmentary side elevational view of the second cutter assembly looking in
the direction of arrows XV-XV shown in Fig. 14;
Fig. 16 is an enlarged, fragmentary view looking in the direction of arrows XVI-XVI
shown in Fig. 11;
Fig. 17 is a sectional plan view taken along plane XVII-XVII of Fig. 16;
Figs. 18 and 18A are sectional plan views taken along plane XVIII-XVIII of Fig. 16;
Fig. 19 is a fragmentary elevational view of the third cutter assembly taken along plane
XIX-XIX of Fig. 18;
Fig. 20 is also a fragmentary elevational view at a right angle to that shown in Fig. 19,
taken along plane XX-XX of Fig. 18;
Fig. 21 is a side elevational view of a fourth cutter assembly in the alternate embodiment
of this invention; and
Fig. 22 is another elevational view of the cutter assembly shown in Fig. 21, looking in
the direction of arrows XXII-XXII shown in Fig. 21.
2161815
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of the following description, the terms "upper," "lower," "right," "left,"
"front," "rear," "vertical," "horizontal," and derivatives or equivalents thereof shall relate to the
invention as oriented in Fig. 2. It is understood that the invention may assume various
5 alternative orientations, except where expressly specified to the contrary. It is also understood
that the specific devices and processes illustrated in the attached drawings, and described in the
following specification, are simply exemplary embodiments of the inventive concepts defined in
the appended claims. Hence, specific dimensions and other physical characteristics relating to
the embodiments disclosed herein are not to be considered limi~ing unless the claims expressly
10 state otherwise.
The device described below is intended to remove excess material from a welded joint of
components formed by the extrusion of polymeric material. For example, plastic window sashes
and door frames have been manufactured from extruded materials for some time. Although the
following description may be specific to extruded work pieces, such as shown in Fig. 4, it is not
15 contemplated to be a limitation and may be used to trim other products.
As shown generally in Fig. 1, the automatic trimming device 10 of this invention includes
a base assembly 12 enclosed within a cabinet 14 provided with an access door 16. Contained
behind access door 16 may be a power supply connection and other circuitry used to operate
device 10, including a microprocessor for controlling the operation of the device 10. Specifics
20 of these features will be described in greater detail below. An upper work surface 18 of the
cabinet 14 includes an upper cabinet or cover 20 for preventing accidental access to certain
components of device 10. The upper cabinet 20 may be attached to base assembly 12 in a
variety of ways in order to provide access to the components therein. For example, as illustrated
in Fig. 2 and partially in Fig. 3, cabinet 20 may be attached by a hinge 26 to upper work
25 surface 18. In this fashion, upper cabinet 20 may be opened and rotated about hinge 26. One or
more handle assemblies, not shown, may be located on the upper cabinet assembly to provide a
hand-hold to open and close the cabinet. Depending from the front of cabinet 14 and disposed
substantially horizontal and at the approp~iate elevation, is a support shelf 22 used to support the
work piece being trimmed. Shelf 22 may have a distal edge supported with respect to the base
30 assembly 12 by a support rod 24. It is plefell~d that support shelf 22 be a frame or lattice-type
configuration in contrast with solid shelf such that weight is reduced and waste from the
Ll;lllllling process does not build up and is allowed to fall to the floor.
2161815
Referring to Figs. 2-5, device 10 includes a locating assembly 30 disposed on the upper
work surface 18 for providing an accurate and reliable template for positioning the work product
on device 10, a first cutter or knife assembly 32 disposed on a portion of the locating assembly,
a second and a third cutter assembly 34, 36, respectively, disposed on work surface 18 on a side
5 of locating assembly 30 opposite that cont~ining the first cutter assembly 32.Locating assembly 30 includes a base plate 40 attached to upper work surface 18 by a
plurality of fasteners extending through elongated slots (not shown) to allow horizontal adjust-
ment of base plate 40 on work surface 18. To assure that movement of base plate 40 is along a
pred~te~ ed axis, channel plates 42 may be fixed to upper surface 18 and located immediately
10 adjacent the lateral edges of base plate 40 to act as a channel guide. It is pler~--.,d that a front
portion of base plate 40 is cantilevered out from work surface 18, for reasons which will be
apparent below.
Extending upwardly from base plate 40 are a pair of stops or locating blocks 46a, 46b
and detachably fastened to base plate 42 by a plurality of fasteners 48. In the embodiment
15 shown, stops 46a, 46b are spaced apart from each other and oriented at a right angle with respect
to the other. The respective angular orientation of stops 46a, 46b may be adjusted by providing
the approp.iate slots or combination of tapped holes or the like to receive the fasteners 48. In
this way, the gap 49 between the stops may also be adjusted. Mounted to a back side of at least
one locating block, such as 46b, and mounted in a hole extending horizontally through the
mounted proximate work surface 18 may be a proximity sensor 47. Sensor 47 is intended to
sense when a work piece, such as 35 (Fig. 4), has been located in position against locating
blocks 46a, 46b. When true, sensor 47 sends a signal to the programmable logic control or
microprocessor inside the cabinet 14. Such sensors are conventional sensors available as stock
items that can be purchased from electrical supply outlets.
Slidably disposed on base plate 40 is an interior locating plate 50 having a portion of its
peripheral edge 52 substantially conforming to the angular orientation of the locating
blocks 46a, 46b. As shown in Fig. 3, locating plate 50 is generally triangular in shape with the
base of the triangle oriented toward the front of device 10. Extending through locating plate 50
are a pair of elongate holes or slots 54 having a longitll~lin~l axis oriented generally
30 perpendicular to the base edge 56 which are configured to receive shoulder bolts 58 and retain a
hold-down member 60. Hold-down member 60 lies immediately adjacent the upper surface of
locating plate 50 for the purpose of m~int~ining locating plate 50 against base plate 40 while
allowing locating plate 50 to move between first and second positions dictated by slots 54.
-6-
. ~16l8l5
. .
Locating plate 50 may be moved between the first position proximate locating blocks 46a, 46b,
and the second position distant from blocks 46a, 46b by a pair of actuators 62a, 62b fixed by a
flange 66 to the front portion 44 of base plate 40, and with the ends of the actuator arms 68
pivotally coupled to locating plate 50.
Locating assembly 30 includes a clamp assembly 70 (Figs. 2-4) formed by a cross
member 72 supported above locating blocks 46a, 46b by cylindrical guides 74a, 74b. Slidably
received on guides 74a, 74b and spanning the di~t~nre therebetween is a sliding beam 76.
Beam 76 includes a hole 77 at each end of the beam having a diameter slightly greater than
guide 74a, 74b to allow beam 76 to slide up and down along the guides while m~int~ining a
10 generally horizontal orientation. Beam 76 is actuated between a first retracted position and a
second extended position by an actuator 78 mounted to cross member 72 and with the end of the
actuator arm coupled to the beam 76. Depending from sliding beam 76 are at least one, and
preferably a plurality of, pins 78 which are configured to engage the uppermost surface of the
work piece with beam 76 in the extended position.
In Fig. 4, first cutter assembly 32 is configured to trim the interior corner 33 of the work
piece 35 using a pair of knife assemblies, each disposed on interior locating plate 50 (Figs. 2 and
3) proximate the peripheral edge which substantially conforms to the angular orientation of the
locating blocks 46a, 46b. Each knife assembly 32 includes an actuator 80 coupled horizontally
to plate 50 by a block 82 with the actuator arms 84 oriented toward the apex 55 of the base
20 plate 50. Attached to the ends of the actuator arms may be mounting blocks 86 which, in turn,
may be attached to the knife blades 88 described in greater detail below. Alternatively, the knife
blades 88 may be coupled directly to the actuator arms 84, such as shown generally in Fig. 4.
Located on a side of locating blocks or stops 46 opposite that cont~ining the first cutter or
knife assembly 32 is the second cutter assembly 34 (see Figs. 4 and 5). The second cutter
25 assembly extends from the interior of cabinet 14 up through a slot or opening 90 in the work
surface 18 and generally includes a drive assembly such as an electric motor 92 mounted to the
lower surface of a carriage 94. The drive shaft or spindle 96 of motor 92 extends through the
carriage 94 and up through opening 90. The electric motor may be coupled to a flexible drive
coupling 98 to spindle 96 contained within a housing 99 also mounted to carriage 94. The upper
30 end of spindle or drive shaft 96 is configured to receive at least one shaper or cutter head 100
retained on shaft 96 in a conventional manner. The particular shape of cutter head 100 is
especially adapted and configured to substantially conform to the profile of the outer surfaces of
the work piece. The shaper assembly engages the work piece tangentially by the translational
2161815
movement of carriage 94 along guide bars 102 slidably received within pillow block bearings 104
mounted on carriage 94. An actuator (not shown) interconnects carriage 94 to the interior of
cabinet 14 to move carriage 94 from its generally retracted position proximate one side of
cabinet 14 to its fully extended position across a centerline of the cabinet and back again. The
5 actuator used to translate the shaper/cutter assembly may be substantially the same actuator as
that mentioned above, with the exception that it has a longer actuator arm to provide the required
travel distance.
Adjacent shaper/cutter assembly 34 is the third cutter assembly 36, which, in this
embodiment, is configured to remove the excess material from the lateral surfaces of the work
10 piece. The third cutter or scarf knife assembly 36 is configured to operate in a direction
generally normal to the work piece and, thus, is disposed upon an axis extending through the gap
49 between locating blocks 46a, 46b. The scarf knife assembly 36 generally includes a
frame 110 fixed to upper work surface 18 and straddling an elongate opening 112. Frame 110
includes left and right track members 114, 116 located opposite each other across opening 112
15 and each having a channel 118 extending the length of the interior surface or side. Disposed
between frame member 114, 116 and slidably received within channel 118 by lugs 123, is a
vertical beam 122. Beam 122 is configured to translate along channels 118 in a substantially
horizontal plane from one end of frame members 114, 116 to the other. Translation of vertical
beam 122 is achieved by actuator assembly 124 mounted to block 128 proximate the rear
20 edge 130 of work surface 18 with the actuator arm 132 coupled thereto.
Coupled to vertical beam 122 are upper and lower knife carriers 134, 136, respectively.
Each may be fastened to vertical beam 122 by a clamp or vice fastener 137 extending through an
elongate slot defined in beam member 122 to allow vertical adjustment of the knife
carriers 134, 136. Each knife carrier has an exterior channel 142 configured to receive a
25 respective scarf knife blade 144. Each scarf knife blade is preferably cantilevered out from
slot 142 and retained therein by a bolt 146 which extends through each knife blade 144 and is
threaded into the respective knife carrier. A spring 148 is provided between the head of the
fastener and the top of the knife blade to allow the blade to move along the shaft of the bolt 146
under the compressive force of the spring 148. An adjustment screw 150 extends through
30 blade 144 between bolt 146 and the vertical beam 122, to adjust the cant or pitch of the blade
about bolt 146.
All of the actuators described above are preferably air linear actuators or similar
hydraulic motors which convert fluid pleS~ule into useful, mechanical work. Each actuator is
-8-
2 1 6 1 8 ~ 5
preferably coupled by a pair of air pressure lines to a manifold configured to actuate each of the
air cylinders upon receipt of an electrical signal generated by a programmable circuit. For
example, the manifold may be comprised of MACTM remote air pilot and solenoid files such as
available under the 900 Series and 55, 56 Series bodies. Each solenoid valve manifold may
5 receive its input from a programmable logic control circuit disposed behind the access door 16
within cabinet 12. One embodiment of a program for such a circuit is shown in Appendix A.
The programmable local control sends an appropliate output to the air manifold to actuate the
respective air cylinders in a predetermined order to carry out the operation of the device 10.
In operation, the operator locates the work piece, such as a welded, extruded window
10 sash or door frame, on the product support shelf such that the corner of the work piece is urged
against locating blocks 46a, 46b and allowed to rest on base plate 40. With the work piece in
this position, the operator then steps on peddle 28 (Fig. 1) to run the programmable logic control
circuit, controlled by a specific program such as set out in Appendix A. The programmable
logic control circuit preferably first causes the actuation of cylinders 62a, 62b to move interior
15 locating plate 50 from a retracted position proximate the front edge of device 10 to an extended
position proximate locating blocks 46a, 46b, thus forcing the work product into gap 49. Once
the work product 35 is appropliately located against blocks 46a, 46b detected by sensor 47, the
programmable logic control circuit causes actuator 80 to extend, thus forcing beam 76 and
pins 78 dowllwaldly against the upper surface of the work product to hold the work piece against
20 base plate 40. In the preferred embodiment, the programmable logic control circuit then actuates
the first cutter assembly 32 to trim the interior corners of the work product by causing the
actuators 80a, 80b to act sequentially, driving knife blades 88 along the interior surface and into
the corner to trim the excess material from the welded joint. Substantially simlllt~n~ously with
the ~l;lllllli~g of the interior corners of the work piece, the programmable logic control may
25 cause the actuator coupled to the shaper/cutter carriage 94 to actuate, thus drawing the
shaper/cutter assembly 34 across the exterior corner of the work piece to trim any excess
material the outer edge from the welded joint. The shaper head 34 may make two passes across
the work piece as it moves from the first position to the second position and back again. In an
alternate embodiment, the shaper head may make a single pass translating from one side of the
30 cabinet to an opposite side of the cabinet in one cycle. The purpose of locating the shaper head
laterally to one side of the cabinet is to provide the scarf knife assembly access to the work
plece.
2i61815
Once the shaper head assembly has made its pass across the exterior edge of the product,
the programmable logic control circuit causes the actuator 124 on the scarf knife assembly 36 to
extend, enabling the tips of the scarf knife blades 144, under pressure controlled by springs 148,
to engage the lateral surfaces of the work piece and remove excess material from the welded
5 joint. After the scarf knife assembly makes its pass, it retracts and the cycle is completed until
the operator steps on peddle 28 again to renew the cycle.
Referring to Figs. 8-11, an alternate and preferred embodiment of the automatic ~ ing
device 210 includes a base assembly 212 preferably formed from a cabinet or box-like structure
214 having a plurality of upright interconnected walls 216 supporting an upper work surface 218.
10 One of walls 214 may include an access door behind which may be located a programmable
circuit including a microprocessor, described in greater detail below, for operating the automatic
~l;lllllling device 210. The access door may also provide access to a connection to a power cord
which provides high voltage (220 VAC power) to the circuitry and other components of the
device. It is preferred that the access door include a latch which interrupts power to the device
lS 210 or otherwise requires the operator to disconnect the electrical power to the device 210 prior
to gaining access through the door.
The upper work surface 218 of the cabinet 214 includes an upper cabinet or safety cover
220 which prevents accidental access to various components of device 210 while operating. As
is well-known in industry, a safety switch may be provided to cover 220 such that all power to
20 the components therein is interrupted and/or that safety brakes are automatically activated to stop
movement of the components. Cover 220 preferably is made from sheet metal, like cabinet 214,
and attached to cabinet 214 by a hinge or other coupling similar to those described above.
Attached to the front of cabinet 214 at or above upper work surface 218 is a support shelf
222 oriented substantially parallel to work surface 218. It is plcfellcd that shelf 222 have a
25 frame or lattice-like configuration to reduce its weight and to allow debris from the work piece
to fall to the floor. Depending upon the distance shelf 222 extends o ulw~ldly from the base
cabinet 214; the distal end of the shelf 222 may be supported by a brace, strut, or rod (not
shown).
The embodiment of the automatic trimming device shown in Figs. 9-11 includes a
30 locating assembly 230 fixed to the upper work surface 218 for providing a repetitively accurate
and reliable template for positioning a work piece or product, such as a welded extruded window
or door frame, in the llillllllil-g device 210. Device 210 also includes a cutter or shaper
assembly 232 (Figs. 11, 12, and 13) and a scarf or knife assembly 234 (Figs. 11, 14, and 15)
-10-
2161815
mounted to the upper work surface 218 and concealed or covered by upper cabinet 220. A third
cutter or trim assembly 236 (Figs. 11, 14, and 15) for trimming an interior surface of the work
piece cooperates with, and forms a part of, locating assembly 230 located toward a front edge of
the upper work surface 218.
Referring to Figs. 12 and 13, the shaper head assembly 232 is located generally in the
central portion of upper work surface 218, extending through an opening 240 formed on surface
218 of sufficient dimension to provide full translation or travel of the shaper assembly along a
horizontal axis, preferably tangent to a corner of the work piece being trimmed, and shown
generally by line A-A in Fig. 12. Shaper assembly 232 generally includes a drive assembly 242
having an electric motor 244, preferably 440V DC, 60 Hz motor available from U.S. Electrical
Motors Division of Emerson Electric Co. of Milford, Conn~cticllt, capable of rotating at 3500
RPM. Motor 244 is preferably suspended from a carriage generally indicated as 246 having four
bushing bearings 249 configured to slide along a pair of guide bars or rods 248. Guide bars 248
are interconn~cte~l at opposite ends by frame members 250 which are, in turn, attached by bolts
252 to a lower surface or bottom 254 of upper work surface 218 to mount shaper assembly 232
in a recess or opening 240.
A drive shaft 256 (Figs. 12 and 13) of motor 244 extends upwardly and is interconnected
to a shaper or cutter head 258 extending above surface 218 by a shaft or spindle 260
concentrically disposed for rotation in a cylindrical housing 252 fixed to an upper surface of
carriage 256 by one or more roller bearings 264, 266 such as taper roller bearings available from
NSK of Ann Arbor, Michigan, and designated LM67048, LM67010, LM29749, and LM29710.
A lower end 268 of spindle 260 is interconnected to motor shaft 256 by a flexible coupling 270,
having a pair of 7/8 inch bores. One example of such a coupling is Model L-075 available from
Lovejoy Corp.. The opposite end 272 of the spindle 260 above housing 262 is configured to
25 detachably retain a cutter head 258 comprised of a plurality of cutter or shaper blades
sandwiched together to provide the a~propfiate profile to be shaped. The shaper/cutter head 258
is retained on spindle 260 by bushing 276 and screw 278 threaded onto the end 272 of the
spindle 260. At the bottom of the stack of blades forming the shaper head 274, a shoulder 280
is formed on the spindle 260 against which the shaper head is held.
The carriage 246 carrying the shaper/cutter 232 is moved between first and second posi-
tions, tr~n~l~ting back and forth along line A-A by an actuator 282 having one end 284 of the
actuator cylinder 286 mounted to the lower surface 254 of work surface 218. The free end 288
of the actuator arm 290 is coupled to a far end of frame member 250. It is pr~felled that actu-
2161815
ator 282 be a single spring return actuator such as Model 4-DP-8.0 air actuator available from
Humphrey. It is further pl~felled that cutter assembly 232 be located at a first or resting posi-
tion at the far end of guide rods 248 proximate one side of base cabinet 214. When ~ctll~ted,
cutter assembly 232 translates along guide bars 248 toward the center of work surface 218, mov-
5 ing tangentially to the exterior surface of the work piece being trimmed such that the shaper head274 removes the desired material. Once the stroke is complete, the cycle reverses and cutter
assembly 232 retracts back to its resting position. It is also pl~fell~d that the relative position of
cutter assembly 232 be monitored by proximity switches 292, such as an inductive proximity
switch, Model No. EL1204PPOS, made by Electromatic Controls Corp. Such switches are
10 located at the resting position of cutter assembly 232 and are activated by a bracket 294
extending from carriage 246. It is further pl~r~ d that the free end 288 of actuator arm 290 is
coupled by an actuator joint 296 to the bracket extending between frame member 250 and prox-
imity switch 292.
Referring to Figs. 14 and 15, the scarf knife assembly 234 which is oriented to move
15 along an axis indicated by line B-B (Fig. 14) which is preferably generally perpendicular to the
travel path of shaper assembly 232 described above. The objective of scarf knife assembly 234
is to remove excess material from both the upper and lower surfaces of the work piece as it is
located on ~ ing device 210.
Scarf knife assembly 234 includes a base plate 300 having a pair of spaced apart members
20 or rectangular columns 302, 304 attached thereto such that the long axes of the columns are
oriented vertically and substantially parallel to each other. Each column includes at least one and
preferably two bushing bearings 306, 308 extending thel~lhlough and aligned with a
corresponding bushing bearing in the spaced column. Slidably received in the upper and lower
bearings 306, 308, respectively of each column 302, 304 is a guide rod 310, 312, intercormected
25 at one end 310 by a cross-member 312. The opposite ends 314 on the opposite sides of the two
columns 302, 304 are also interconnected by a vertically oriented beam 316 attached by shoulder
bolts to the guide bars. Cantilevered from opposite ends 318, 320 of beam 316 are upper and
lower knife carriers 322, 324, respectively, attached to the lateral sides 326, 328 of the beam by
corresponding plates 330, 332. Each knife carrier 322, 324 is coupled at one end between plates
30 such as 330, 332. Plates 330, 332 are, in turn, pivotally coupled to beam 316 by dowel pins
336, 338 extending therethrough and into plates 330, 332 (Fig. 15). A compression spring (not
shown) is disposed between the end of each knife carrier 322, 324 and beam 316, to force each
knife carrier and plate (330 and 332) generally toward each other. The colllpressive force of
2161815
each spring may be adjusted by a set screw 340 received in each end of beam 316. The rotation
of each knife carrier 322, 324 and its corresponding plates about dowel pins 336, 338 is
controlled by bolts 344, 346 received in brackets 348, 350 extending laterally behind and away
from beam 316 such that the tip of each bolt 344, 346 can engage one of the plates in each pair
5 inboard of the pivot point along dowel pins 336, 338. By adjusting bolts 344, 346 the distance
between the distal ends 352 of the knife carriers 322, 324 can be adjusted to accommodate a
range of work piece thicknesses or widths. As in the prior embodiment, scarf knife blades 354
are rigidly fixed to the distal end 352 of each knife carrier 322, 324.
Interconn~cting beam 316 and at least a portion of the base 300, preferably column 302 is
10 an actuator 360 configured to translate beam 316 and its associated knife blades 354 along axis
B-B between its first or retracted position proximate column 302 and its fully extended position
distant from column 302. Actuator 306 is preferably an air actuator, Model No. 4-D-9.0
available from Humphrey, wherein a free end 362 of the actuator arm 364 is coupled by a
cylinder joint to a center point of beam 316. The air cylinder 366 is preferably coupled at end
15 368 to column 302. As with the shaper assembly described above, the extent of travel and rest
position of the scarf knife assembly can be detected and/or controlled by proximity switches 368
and 370. Switch 368 is preferably mounted in column 304 and oriented to detect the extension
of the scarf knife assembly 234. A bolt 372 threadably received in cross member 312 may be
threaded in or out to adjust the extension distance. Likewise, proximity switch 370 is mounted
20 in column 302 to face toward beam 316 to detect when beam 316 is retracted to the appl~liate
point.
Referring to Figs. 16 through 18, locating assembly 230 disposed on upper work surface
18 positions and retains the work piece in the appropriate position in the trimming device 210
during the trimming process. Locating assembly 230 includes a horizontal positioning and
25 clamping portion 380 as well as a vertical position and clamping portion 382. The horizontal
positioning and clamping portion 380 includes a base plate 384 (Figs. 16 and 17) fixed to upper
work surface 218 by a pair of clamps 386 eng~ging opposing peripheral edges of the base plate
384 and secured to work surface 218. A plurality of slots or openings 388, 390, and 392
extending through base plate 384 are disposed above and aligned with corresponding openings
30 formed in work surface 218. Between opening or slots 388 and 390, and extending from the
upper surface of base plate 384 are a plurality of rails 394, 396, and 398, all arranged substan-
tially parallel to each other at three triangularly spaced points (Fig. 17).
.. . 2i~1815
Also mounted to the upper surface of base plate 384 are a pair of stops or locating blocks
400, 402 (Fig. 18) fixed in position by fasteners. Stops 400, 402 are spaced apart from each
other by a predetermined distance and oriented substantially perpendicular to each other. The
respective angular orientations of stop 400, 402 may be adjusted by providing the ap~lopliate
5 slots or combination of tapped holes to receive the fasteners. In this way, the gap 404 between
the stops may be changed. The transverse profiles of each stop 400 or 402 may vary, but are
intended to conform closely to the exterior surface of that portion of the work piece being
received. Thus, it is contemplated that recesses or projections may be formed a part thereof as
n~ces~ry. Stops 400, 402 may be made from any rigid material including metal and many poly-
meric substances. Mounted in a hole extending through at least one of the stops 400 or 402 is a
proximity switch 406 intended to determine when a work piece has been located in position
against stops 400, 402. Due to various types of materials trimming device 210 may work on, it
is preferred that proximity switch 406 be of the optical type.
Slidably disposed on rails 394, 396, and 398 and configured to move between a first
retracted position and a second extended position adjacent stops 400, 402 is an interior clamp or
locating assembly 380 interconnected to the rails 394, 396, and 398 by linear bearing such as
shown by 408. Interior clamp 380 generally includes a housing 412 (Fig. 19) having lower and
upper members 414, 416, respectively, both having at least two sides such as 418, 420 which
substantially parallel the angular orientation of stops 400, 402. The rem~ining sides of the hous-
ing may take on any shape. The housing 412 is preferably translated along rails 394, 396, 398
by bearings 408 between the two positions by at least one actuator 422 (Figs. 10, 11, and 16).
Actuator 422 is substantially identical to those described above and includes a cylinder portion
426 mounted at one end to the bottom 254 of surface 218. The arm 430 of actuator 422 has its
free end coupled to a lower surface of lower member 414 preferably by a cylinder coupling.
Spaced from actuator 422 and oriented substantially vertically from the bottom 254 of
surface 218 are at least one, and preferably two, locking assemblies 424 each generally including
an actuator 428 securely fixed in place below surface 218 by a frame member 432, positioning
each actuator such that the actuator arms extend and retract vertically through surface 218 and
into locking registry in sockets 434 (Fig. 16) formed in the lower member 414 of housing 412.
30 It is plefell~d that the locking assemblies are actuated only when housing 412 is translated to its
extended position, urging the work piece against the stops 400, 402 to trim the interior surface.
When in this configuration the locking pins extend and engage holes 434, fixing interior clamp
-14-
2161815
410 in place while the work piece is being trimrned. Locking assemblies 424 preferably use
actuators such as Model No. S-D-1.00 available from Humphreys.
The second or vertical positioning and clamping mechanism 382 includes a cross member
440 supported above stops 400, 402 by a pair of uprights 442, ~ wherein the lower ends of
5 each upright are attached to stops 400, 402. It is preferred that in plan view, cross member 440
be located substantially above the area to receive the work piece for reasons which will be
apparent.
Mounted to cross member 440 is at least one, and preferably a plurality of, vertically
oriented actuators 446, each having a cylinder portion 448 secured to cross member 440 and with
10 the actuator arms 450 extending downwardly through holes in the cross member. The ends of
the actuator arms are mounted with pads or feet 452 adapted to engage the upper surface of the
work piece when extended, and force the work piece downward against stops 400, 402 and base
plate 384.
Referring to Figs. 18 and 18A, housing 412 also retains a pair of knife assemblies 460, 462,
15 each configured to trim an interior surface of the work piece urged against stops 400, 402 by
clamp assembly 380. More particularly, the knife assemblies 460 are provided to an interior
corner of the welded work piece. Each knife assembly 460, 462 includes a knife blade 464 con-
~lgured to slide substantially parallel to side 418 or 420 and along an interior surface of the work
piece. As with stops 400, 402, the profile of each blade 464 closely conforms to the surface of
20 the work piece to be trimmed. Each knife blade 464 is retained 011 a knife carrier 466 mounted
between upper and lower members 414, 416 and configured to slide substantially parallel to the
edge 418 or 420 of housing 412. It is contemplated that carrier 466 may be mounted in tracks or
race formed between flanges or ridges, such as 456 and 458 (Fig. 18), to assure that carrier 466
translates in a linear direction. Each knife carrier 466 is pivotally coupled at one end 468 to a
25 hinge assembly 470. Hinge assembly 470 includes a first member 472 having at one end pivot-
ally coupled to end 468 of carrier 466 and an opposite end 474 pivotally connected to a first end
476 of second member 478. The opposite end 480 of the second member is pivotally coupled at
482 to housing 412 by a dowel pin and thrust washer (not shown). Interconnected to the hinged
iunction formed by ends 474 and 476 is a free end 484 of an actuator arm 486 extending from
30 actuator cylinder 488 pivotally coupled at 490 to housing 412. With actuator arm 486 retracted
in cylinder 488, hinge assembly 472 is bent forcing knife carrier 466 along side 418 or 420 to a
retracted position. With actuator arm 486 extended, hinge assembly 470 becomes extended,
forcing knife carrier 466 to translate parallel to side 418 or 420 When actuator arm 486
2 1 6 1 81 5
retracts, the hinge assembly 470 folds along the hinge line, shortening the distance between
coupling 482 and the end 468 of knife carrier 466 causing the knife carrier 466 to retract along
side 418 or 420 away from the corner of the work piece.
Referring to Figs. 10, 11, 21, and 22, the automatic trimming device 210 may also
5 include a router assembly 500 generally intended to extend upwardly through work surface 218
beneath the work piece to a predetermined point, where the router tip 502 cleans a portion of the
corner inaccessible by the interior knife blade 464.
In a preferred embodiment of the router assembly 500, a base 504 is dependent from
upper work surface 218 or attached to a frame work (not shown) internal to cabinet 214. Base
10 504 has a rail 506 attached thereto, configured to recurve a linear bearing 408 similar to those
used to glide housing 412 along base plate 384. Attached to linear bearing 508 is a carriage 510
cont~ining a mounting bracket 512 for fixing router 514 thereon. Carriage 510 also includes a
laterally extending member 516 configured to be attached to one end of an actuator 518,
preferably the free end of the actuator arm 520. The cylinder 522 is fixed in position, preferably
15 by a pillow block or collar 524 disposed at or toward the lower end of base 504. Collar 524
may also provide a tab 526 for mounting a proximity switch 528 thereon, positioned to detect
when carriage 510 (laterally extending members or router 514) is at its retracted position. To
add flexibility to the router assembly for use on work pieces of a different configuration, mount-
ing bracket 512 may be pivotally coupled to carriage 510 to allow router 514 to be rotated or
20 fixed at a predetermined angle as necessary.
The mode of operation contemplated for this embodiment of the invention is substantially
similar to that described above. It shall be ~s~m~cl that electrical power is provided to the
electrical circuitry necessary to operate the programmable logic control and electric motor for
spinning the shaper assembly. It is also L,l-,rell~d that a supply of pressurized air also be con-
25 nected to an appropliate air manifold/solenoid assembly in order to operate the various pneu-
matic actuators used in the invention. It shall also be assumed that a programmable logic control
circuit is provided to control the sequence of operations following a program similar to that
shown in the Appendix.
Referring back to Figs. 9-21, an operator locates the work piece on work surface 218
30 between stop 400, 402 and horizontal positioning clamp 380, 410. With the work piece gener-
ally positioned, the operator activates the programmable logic control circuit using the program
(Appendix A) to initiate the trimming sequences. It is preferred that the first step is the clamp-
ing of the work piece horizontally against stops 400, 402 by the traverse of interior clamp
-16-
21618~5
assembly 410 moved by actuator 422 and locked into position by locking actuators 424. Thework piece is also urged dowllwardly against stops 400, 402 and surface 218 by vertical clamp
assembly 382. Although the following steps may occur in sequence, it is preferred that the inte-
rior surface of the work piece is trimmed first by the actuation of knife assemblies 460, 462 in
5 housing 412, followed by the extension of router assembly 500 to clean the weld rem~ining from
knives 464 after they retract. Once the interior trim is complete, it is prefelled that shaper
assembly 232, already spinning at approximately 3500 RPM, is tr~n~l~ted along axis A-A to
move cutter head 258 across the exterior surface of the work piece extending through gap 404.
At the end of its pass determined by a proximity switch, the programmable logic control circuit
10 (PLC) causes the air manifold to redirect the air to retract the shaper assembly to its resting posi-
tion. With the shaper back in its starting position, scarf knife assembly is actuated by the PLC
tr~n~l~ting the upper and lower knife blades 354 to trim any excess material from the lateral
surfaces of the work piece. Again, the proximity switch detecting the cross member or other
lèfelellce signals the PLC to retract the air cylinder to return the scarf knife assembly to its
15 original position. Once all of the steps have been completed, the PLC finishes the program by
retracting the actuators of the locating assembly 230, allowing the work piece to be removed and
repositioned or moved on down the assembly line.
The above description is considered that of the plefelled embodiments only. Modifi-
cation of the invention will occur to those skilled in the art and to those who make and use the
20 invention. Therefore, it is understood that the embodiments shown in the drawings and described
above are merely for illustrative purposes and are not intended to limit the scope of the
invention, which is defined by the following claims.