Compliant cutoff saw assembly

#The present invention relates generally to the field of metal casting. More particularly the present invention relates to the cutoff of excess material on metal castings after it has been removed from the mold. In even greater particularity the present invention relates to the removal of riser or gate remnants after a cast part has been removed from the mold and to a process for perfecting the cutoff operation by conjunctively using a robot and a compliant cutoff saw.

#In the casting arts, molten metal is poured into a mold through an opening in the top of the mold with a certain excess metal filling the channel to the mold cavity. When multiple parts are cast in the same casting vessel, the mold will include channels in the form of a sprue to each cavity for each part, which will create undesired dross on the outer surface of the casting once the molten metal has hardened into the casting. The excess metal, such as those referred to as risers or gates, is frequently required to be removed by a cutoff or grinding operation in order for the casting to perform the purpose intended.

#There are several common practices used by foundries to remove the risers or gates from the castings. These practices include, but are not limited to, removal of the riser by means of a gas torch, a grinder, a conventional cutting blade or saw, or some similar machine for forcefully removing the dross. Moreover, after the gates or risers have been removed from the casting through any of these methods, the operator commonly has to further grind or finish the casting due to an uneven cut caused by the respective trimming method.

#A compliant cutoff saw assembly embodying the features of the present invention is depicted in the accompanying drawing which form a portion of this disclosure and wherein:

#FIG. 1 is a side elevational view of the present invention of a compliant cutoff saw assembly.

#Looking now to FIG. 1, the present invention of a compliant cutoff saw assembly 10 is illustrated. The compliant cutoff saw assembly 10 encompasses a robot assembly 12 used in conjunction with a cutting apparatus 20 to remove undesired metal extensions from a casting 16. The compliant cutoff saw assembly 10 has the ability to cooperatively and contemporaneously control both the position of the casting 16 as well as the compliance force exerted by the cutting apparatus 20 on the casting 16 during the incision. The combination of these controls allows the compliant cutoff saw assembly 10 to provide a clean and even cut into the casting 16, which reduces or eliminates the amount of work required to finish the casting 16 once the metal extensions have been removed.

#Referring to FIG. 1, the first component of the present invention is the robot assembly 12 which includes a multi-positional robot arm 14 that is connected to a system controller 18. A tooling clamp 15 is connected to the unattached end of the robot arm 14, with the tooling clamp 15 being used to engage and securely hold the casting 16 to be cut. The robot arm 14 is able to move in three dimensions, and can therefore position the casting 16 in any dimension as desired by the operator. Consequently, the compliant cutoff saw 20 will be able to cut any side, surface or portion of the casting 16 as desired by the operator of the compliant cutoff saw assembly 10.

#The second component of the present invention is the cutting apparatus 20 which preferably includes a frame 22 that is sturdily positioned on a ground or floor surface. The frame 22 comprises a mounting assembly 24 that preferably includes a shaft and a pair of bearings, with a support beam 26 being pivotally affixed to the mounting assembly 24. The support beam 26 includes a lower end 28a and an upper end 28b, with a drive motor 30 being attached to the lower end 28a and a cutoff blade 32, such as an abrasive blade, carbide blade, diamond-tipped blade or other cutting device, being rotatably attached to the upper end 28b in the preferred embodiment. The drive motor 30 is mechanically connected to the cutoff blade 32 to drive and control the rotation of the cutoff blade 32 as desired by the operator pursuant to the requirements of the casting 16 being cut. Moreover, the drive motor 30 is connected to a drive system 40, which preferably includes a vector drive, such that the drive system 40 can control and vary the operation of the drive motor 30 and thus the speed of rotation of the cutoff blade 16. The drive system 40 is further connected to said system controller 18 via drive cable 42, such that the drive system 40 can receive communications from the system controller 18 directing operation of the drive motor 30.